Smart cartridge wake up operation and data retention

ABSTRACT

An electronic system for a surgical instrument is disclosed. The electronic system comprises a main power supply circuit configured to supply electrical power to a primary circuit. A supplementary power supply circuit configured to supply electrical power to a secondary circuit. A short circuit protection circuit coupled between the main power supply circuit and the supplementary power supply circuit. The supplementary power supply circuit is configured to isolate itself from the main power supply circuit when the supplementary power supply circuit detects a short circuit condition at the secondary circuit. The supplementary power supply circuit is configured to rejoin the main power supply circuit and supply power to the secondary circuit, when the short circuit condition is remedied.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/170,576, entitledSMART CARTRIDGE WAKE UP OPERATION AND DATA RETENTION, filed Oct. 25,2018, now U.S. Patent Application Publication No. 2019/0125345, which isa continuation application claiming priority under 35 U.S.C. § 120 toU.S. patent application Ser. No. 14/479,098, entitled SMART CARTRIDGEWAKE UP OPERATION AND DATA RETENTION, filed Sep. 5, 2014, which issuedNov. 20, 2018 as U.S. Pat. No. 10,135,242, the entire disclosures ofwhich are hereby incorporated by reference herein.

This application is related to U.S. patent application Ser. No.14/479,103, entitled CIRCUITRY AND SENSORS FOR POWERED MEDICAL DEVICE,now U.S. Pat. No. 10,111,679, U.S. patent application Ser. No.14/479,119, entitled ADJUNCT WITH INTEGRATED SENSORS TO QUANTIFY TISSUECOMPRESSION, now U.S. Pat. No. 9,724,094, U.S. patent application Ser.No. 14/478,908, entitled MONITORING DEVICE DEGRADATION BASED ONCOMPONENT EVALUATION, now U.S. Pat. No. 9,737,301, U.S. patentapplication Ser. No. 14/478,895, entitled MULTIPLE SENSORS WITH ONESENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR INTERPRETATION, now U.S.Pat. No. 9,757,128, U.S. patent aplication Ser. No. 14/479,110, entitledPOLARITY OF HALL MAGNET TO IDENTIFY CARTRIDGE TYPE, now U.S. Pat. No.10,016,199, U.S. patent application Ser. No. 14/479,115, entitledMULTIPLE MOTOR CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Pat. No.9,788,836, and U.S. patent application Ser. No. 14/479,108, entitledLOCAL DISPLAY OF TISSUE PARAMETER STABILIZATION, now U.S. PatentApplication Publication No. 2016/0066913, each of which was filed onSep. 5, 2014 and each of which is incorporated herein by reference inits entirety.

BACKGROUND

The present embodiments of the invention relate to surgical instrumentsand, in various circumstances, to surgical stapling and cuttinginstruments and staple cartridges therefor that are designed to stapleand cut tissue.

SUMMARY

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and a short circuit protection circuit coupledbetween the main power supply circuit and the supplementary power supplycircuit. The supplementary power supply circuit is configured to isolateitself from the main power supply circuit when the supplementary powersupply circuit detects a short circuit condition at the secondarycircuit. The supplementary power supply circuit is configured to rejointhe main power supply circuit and supply power to the secondary circuit,when the short circuit condition is remedied.

In one embodiment, the short circuit protection circuit is configured tomonitor one or more short circuit conditions. In one embodiment, theshort circuit protection circuit is configured to lockout the firing ofthe surgical instrument when a short circuit event is indicated. In oneembodiment, the electronic system comprises a plurality of supplementaryprotection circuits networked together to isolate, detect, or protectother circuit functions.

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and a sample rate monitor coupled between themain power supply circuit and the supplementary power supply circuit,wherein the sample rate monitor is configured to limit sample ratesand/or duty cycle of the secondary circuit when the surgical instrumentis in a non-sensing state.

In one embodiment, the electronic system further comprises a devicestate monitor coupled to the primary circuit, the device state monitorconfigured to sense a state of various electrical and mechanicalsubsystems of the surgical instrument. In one embodiment, the samplerate monitor operates in conjunction with the device state monitor. Inone embodiment, the device state monitor is configured to sense thestate of an end effector of the surgical instrument in an unclamped(State 1), a clamping (State 2), or a clamped (State 3) state ofoperation and wherein the sample rate monitor is configured to set thesample rate and/or duty cycle for the secondary circuit based on thestate of the end effector determined by the device state monitor. In oneembodiment, the sample rate monitor is configured to set the duty cycleto about 10% when the end effector is in State 1, to about 50% when theend effector is in State 2, or about 20% when the end effector is inState 3.

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and an over current/voltage protection circuitcoupled between the main power supply circuit and the supplementarypower supply circuit, wherein the over current/voltage protectioncircuit is configured to isolate current from the main power supplycircuit when the secondary circuit experiences higher levels of currentor voltage than expected.

In one embodiment, the over current or the over voltage condition isremedied, the supplementary power circuit rejoins the main power supplycircuit and is configured to supply power to the secondary circuit. Inone embodiment, the over current/voltage protection circuit isconfigured to lockout the firing of the surgical instrument when theover current/voltage condition event is indicated, when an overcurrent/voltage condition is detected. In one embodiment, the overcurrent/voltage protection circuit is configured to indicate an overcurrent/voltage condition to an end user of the surgical instrument,when an over current/voltage condition is detected. In one embodiment,the over current/voltage protection circuit is configured to lock-outthe surgical instrument from being fired or lock-out other operations ofthe surgical instrument, when an over current/voltage condition isdetected.

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and a reverse polarity protection circuitcoupled between the main power supply circuit and the supplementarypower supply circuit, wherein the reverse polarity protection circuit isconfigured to isolate the secondary circuit from the main power supplycircuit when a reverse polarity voltage is applied to the secondarycircuit.

In one embodiment, the reverse polarity protection circuit is configuredto isolate the supplementary power supply circuit from the secondarycircuit when the reverse polarity voltage is applied to the secondarycircuit. In one embodiment, the reverse polarity protection circuit isconfigured to rejoin the supplementary power supply circuit to supplypower to the secondary circuit when the reverse polarity voltagecondition is remedied. In one embodiment, the reverse polarity circuitcomprises a relay switch comprising an input coil and output contactscoupled to the secondary circuit, wherein the input coil is in serieswith a diode configured to block current flow through the input coil ofthe relay switch when a voltage of a first polarity is applied to thesecondary circuit through the output contacts. In one embodiment, thediode is configured to enable current flow through the diode and theinput coil when a voltage of a second polarity is applied to thesecondary circuit, wherein the current through the input coil energizesthe relay switch to disconnect the output voltage of the second polarityfrom the secondary circuit.

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and a sleep mode monitor coupled between themain power supply circuit and the supplementary power supply circuit,wherein the sleep mode monitor is configured to indicate one or moresleep mode conditions.

In one embodiment, the electronic system further comprises a devicestate monitor coupled to the primary circuit, the device state monitorconfigured to sense a state of various electrical and mechanicalsubsystems of the surgical instrument. In one embodiment, the sleep modemonitor operates in conjunction with the device state monitor. In oneembodiment, the device state monitor is configured to sense the state ofan end effector of the surgical instrument in an unclamped (State 1), aclamping (State 2), or a clamped (State 3) state of operation andwherein the sleep mode monitor is configured to place the secondarycircuit in sleep mode when the surgical instrument is in the unclamped(State 1) and to place the secondary circuit in awake mode when thesurgical instrument is in either in the clamping (State 2) or theclamped (State 3).

In one embodiment, an electronic system for a surgical instrument isprovided. The electronic system comprises a main power supply circuitconfigured to supply electrical power to a primary circuit; asupplementary power supply circuit configured to supply electrical powerto a secondary circuit; and a temporary power loss circuit coupledbetween the main power supply circuit and the supplementary power supplycircuit, wherein the temporary power loss circuit is configured toprovide protection against intermittent power loss in the secondarycircuit. In one embodiment, the temporary power loss circuit isconfigured to deliver continuous power for short periods of time in theevent power from the main power supply circuit is interrupted.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the various embodiments of the invention,and the manner of attaining them, will become more apparent and theembodiment of the invention itself will be better understood byreference to the following description of embodiments of the embodimentof the invention taken in conjunction with the accompanying drawings,wherein:

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaftassembly and surgical instrument of FIG. 1;

FIG. 3 is another exploded assembly view showing portions of theinterchangeable shaft assembly and surgical instrument of FIGS. 1 and 2;

FIG. 4 is an exploded assembly view of a portion of the surgicalinstrument of FIGS. 1-3;

FIG. 5 is a cross-sectional side view of a portion of the surgicalinstrument of FIG. 4 with the firing trigger in a fully actuatedposition;

FIG. 6 is another cross-sectional view of a portion of the surgicalinstrument of FIG. 5 with the firing trigger in an unactuated position;

FIG. 7 is an exploded assembly view of one form of an interchangeableshaft assembly;

FIG. 8 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIG. 7;

FIG. 9 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIGS. 7 and 8;

FIG. 10 is a cross-sectional view of a portion of the interchangeableshaft assembly of FIGS. 7-9;

FIG. 11 is a perspective view of a portion of the shaft assembly ofFIGS. 7-10 with the switch drum omitted for clarity;

FIG. 12 is another perspective view of the portion of theinterchangeable shaft assembly of FIG. 11 with the switch drum mountedthereon;

FIG. 13 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anunactuated position;

FIG. 14 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 13;

FIG. 15 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 13 and 14;

FIG. 16 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and a firing trigger thereof in an unactuatedposition;

FIG. 17 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 16;

FIG. 18 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 16 and 17;

FIG. 18A is a right side elevational view of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and the firing trigger thereof in an actuatedposition;

FIG. 19 is a schematic of a system for powering down an electricalconnector of a surgical instrument handle when a shaft assembly is notcoupled thereto;

FIG. 20 is an exploded view of one embodiment of an end effector of thesurgical instrument of FIG. 1;

FIGS. 21A-21B is a circuit diagram of the surgical instrument of FIG. 1spanning two drawings sheets;

FIG. 22 illustrates one instance of a power assembly comprising a usagecycle circuit configured to generate a usage cycle count of the batteryback;

FIG. 23 illustrates one embodiment of a process for sequentiallyenergizing a segmented circuit;

FIG. 24 illustrates one embodiment of a power segment comprising aplurality of daisy chained power converters;

FIG. 25 illustrates one embodiment of a segmented circuit configured tomaximize power available for critical and/or power intense functions;

FIG. 26 illustrates one embodiment of a power system comprising aplurality of daisy chained power converters configured to besequentially energized;

FIG. 27 illustrates one embodiment of a segmented circuit comprising anisolated control section;

FIG. 28 illustrates one embodiment of an end effector comprising a firstsensor and a second sensor;

FIG. 29 is a logic diagram illustrating one embodiment of a process foradjusting the measurement of the first sensor based on input from thesecond sensor of the end effector illustrated in FIG. 28;

FIG. 30 is a logic diagram illustrating one embodiment of a process fordetermining a look-up table for a first sensor based on the input from asecond sensor;

FIG. 31 is a logic diagram illustrating one embodiment of a process forcalibrating a first sensor in response to an input from a second sensor;

FIG. 32A is a logic diagram illustrating one embodiment of a process fordetermining and displaying the thickness of a tissue section clampedbetween an anvil and a staple cartridge of an end effector;

FIG. 32B is a logic diagram illustrating one embodiment of a process fordetermining and displaying the thickness of a tissue section clampedbetween the anvil and the staple cartridge of the end effector;

FIG. 33 is a graph illustrating an adjusted Hall effect thicknessmeasurement compared to an unmodified Hall effect thickness measurement;

FIG. 34 illustrates one embodiment of an end effector comprising a firstsensor and a second sensor;

FIG. 35 illustrates one embodiment of an end effector comprising a firstsensor and a plurality of second sensors;

FIG. 36 is a logic diagram illustrating one embodiment of a process foradjusting a measurement of a first sensor in response to a plurality ofsecondary sensors;

FIG. 37 illustrates one embodiment of a circuit configured to convertsignals from a first sensor and a plurality of secondary sensors intodigital signals receivable by a processor;

FIG. 38 illustrates one embodiment of an end effector comprising aplurality of sensors;

FIG. 39 is a logic diagram illustrating one embodiment of a process fordetermining one or more tissue properties based on a plurality ofsensors;

FIG. 40 illustrates one embodiment of an end effector comprising aplurality of sensors coupled to a second jaw member;

FIG. 41 illustrates one embodiment of a staple cartridge comprising aplurality of sensors formed integrally therein;

FIG. 42 is a logic diagram illustrating one embodiment of a process fordetermining one or more parameters of a tissue section clamped within anend effector;

FIG. 43 illustrates one embodiment of an end effector comprising aplurality of redundant sensors;

FIG. 44 is a logic diagram illustrating one embodiment of a process forselecting the most reliable output from a plurality of redundantsensors;

FIG. 45 illustrates one embodiment of an end effector comprising asensor comprising a specific sampling rate to limit or eliminate falsesignals;

FIG. 46 is a logic diagram illustrating one embodiment of a process forgenerating a thickness measurement for a tissue section located betweenan anvil and a staple cartridge of an end effector;

FIG. 47 illustrates one embodiment of a circular stapler;

FIGS. 48A-48D illustrate a clamping process of the circular staplerillustrated in FIG. 47, where FIG. 48A illustrates the circular staplerin an initial position with the anvil and the body in a closedconfiguration, FIG. 48B illustrates that the anvil is moved distally todisengage with the body and create a gap configured to receive a tissuesection therein, once the circular stapler 3400 is positioned, FIG. 48Cillustrates the tissue section compressed to a predetermined compressionbetween the anvil and the body, and FIG. 48D illustrates the circularstapler in position corresponding to staple deployment;

FIG. 49 illustrates one embodiment of a circular staple anvil and anelectrical connector configured to interface therewith;

FIG. 50 illustrates one embodiment of a surgical instrument comprising asensor coupled to a drive shaft of the surgical instrument;

FIG. 51 is a flow chart illustrating one embodiment of a process fordetermining uneven tissue loading in an end effector;

FIG. 52 illustrates one embodiment of an end effector configured todetermine one or more parameters of a tissue section during a clampingoperation;

FIGS. 53A and 53B illustrate an embodiment of an end effector configuredto normalize a Hall effect voltage irrespective of a deck height of astaple cartridge;

FIG. 54 is a logic diagram illustrating one embodiment of a process fordetermining when the compression of tissue within an end effector, suchas, for example, the end effector illustrated in FIGS. 53A-53B, hasreached a steady state;

FIG. 55 is a graph illustrating various Hall effect sensor readings;

FIG. 56 is a logic diagram illustrating one embodiment of a process fordetermining when the compression of tissue within an end effector, suchas, for example, the end effector illustrated in FIGS. 53A-53B, hasreached a steady state;

FIG. 57 is a logic diagram illustrating one embodiment of a process forcontrolling an end effector to improve proper staple formation duringdeployment;

FIG. 58 is a logic diagram illustrating one embodiment of a process forcontrolling an end effector to allow for fluid evacuation and provideimproved staple formation;

FIGS. 59A-59B illustrate one embodiment of an end effector comprising apressure sensor;

FIG. 60 illustrates one embodiment of an end effector comprising asecond sensor located between a staple cartridge and a second jawmember;

FIG. 61 is a logic diagram illustrating one embodiment of a process fordetermining and displaying the thickness of a tissue section clamped inan end effector, according to FIGS. 59A-59B or FIG. 60;

FIG. 62 illustrates one embodiment of an end effector comprising aplurality of second sensors located between a staple cartridge and anelongated channel;

FIGS. 63A and 63B further illustrate the effect of a full versus partialbite of tissue;

FIG. 64 illustrates one embodiment of an end effector comprising a coiland oscillator circuit for measuring the gap between the anvil and thestaple cartridge;

FIG. 65 illustrates and alternate view of the end effector. Asillustrated, in some embodiments external wiring may supply power to theoscillator circuit;

FIG. 66 illustrates examples of the operation of a coil to detect eddycurrents in a target;

FIG. 67 illustrates a graph of a measured quality factor, the measuredinductance, and measure resistance of the radius of a coil as a functionof the coil's standoff to a target;

FIG. 68 illustrates one embodiment of an end effector comprising anemitter and sensor placed between the staple cartridge and the elongatedchannel;

FIG. 69 illustrates an embodiment of an emitter and sensor in operation;

FIG. 70 illustrates the surface of an embodiment of an emitter andsensor comprising a MEMS transducer;

FIG. 71 illustrates a graph of an example of the reflected signal thatmay be measured by the emitter and sensor of FIG. 69;

FIG. 72 illustrates an embodiment of an end effector that is configuredto determine the location of a cutting member or knife;

FIG. 73 illustrates an example of the code strip in operation with redLEDs and an infrared LEDs;

FIG. 74 illustrates a partial perspective view of an end effector of asurgical instrument comprising a staple cartridge according to variousembodiments described herein;

FIG. 75 illustrates a elevational view of a portion of the end effectorof FIG. 74 according to various embodiments described herein;

FIG. 76 illustrates a logic diagram of a module of the surgicalinstrument of FIG. 74 according to various embodiments described herein;

FIG. 77 illustrates a partial view of a cutting edge, an optical sensor,and a light source of the surgical instrument of FIG. 74 according tovarious embodiments described herein;

FIG. 78 illustrates a partial view of a cutting edge, an optical sensor,and a light source of the surgical instrument of FIG. 74 according tovarious embodiments described herein;

FIG. 79 illustrates a partial view of a cutting edge, an optical sensor,and a light source of the surgical instrument of FIG. 74 according tovarious embodiments described herein;

FIG. 80 illustrates a partial view of a cutting edge, optical sensors,and light sources of the surgical instrument of FIG. 74 according tovarious embodiments described herein;

FIG. 81 illustrates a partial view of a cutting edge, an optical sensor,and a light source of the surgical instrument of FIG. 74 according tovarious embodiments described herein;

FIG. 82 illustrates a partial view of a cutting edge between cleaningblades of the surgical instrument of FIG. 74 according to variousembodiments described herein;

FIG. 83 illustrates a partial view of a cutting edge between cleaningsponges of the surgical instrument of FIG. 74 according to variousembodiments described herein;

FIG. 84 illustrates a perspective view of a staple cartridge including asharpness testing member according to various embodiments describedherein;

FIG. 85 illustrates a logic diagram of a module of a surgical instrumentaccording to various embodiments described herein;

FIG. 86 illustrates a logic diagram of a module of a surgical instrumentaccording to various embodiments described herein;

FIG. 87 illustrates a logic diagram outlining a method for evaluatingsharpness of a cutting edge of a surgical instrument according tovarious embodiments described herein;

FIG. 88 illustrates a chart of the forces applied against a cutting edgeof a surgical instrument by the sharpness testing member of FIG. 84 atvarious sharpness levels according to various embodiments describedherein;

FIG. 89 illustrates a flow chart outlining a method for determiningwhether a cutting edge of a surgical instrument is sufficiently sharp totransect tissue captured by the surgical instrument according to variousembodiments described herein; and

FIG. 90 illustrates a table showing predefined tissue thicknesses andcorresponding predefined threshold forces according to variousembodiments described herein.

FIG. 91 illustrates a perspective view of a surgical instrumentincluding a handle, a shaft assembly, and an end effector;

FIG. 92 illustrates a logic diagram of a common control module for usewith a plurality of motors of the surgical instrument of FIG. 91;

FIG. 93 illustrates a partial elevational view of the handle of thesurgical instrument of FIG. 91 with a removed outer casing;

FIG. 94 illustrates a partial elevational view of the surgicalinstrument of FIG. 91 with a removed outer casing.

FIG. 95A illustrates a side angle view of an end effector with the anvilin a closed position, illustrating one located on either side of thecartridge deck;

FIG. 95B illustrates a three-quarter angle view of the end effector withthe anvil in an open position, and one LED located on either side of thecartridge deck;

FIG. 96A illustrates a side angle view of an end effector with the anvilin a closed position and a plurality of LEDs located on either side ofthe cartridge deck;

FIG. 96B illustrates a three-quarter angle view of the end effector withthe anvil in an open position, and a plurality of LEDs located on eitherside of the cartridge deck;

FIG. 97A illustrates a side angle view of an end effector with the anvilin a closed position, and a plurality of LEDs from the proximal to thedistal end of the staple cartridge, on either side of the cartridgedeck; and

FIG. 97B illustrates a three-quarter angle view of the end effector withthe anvil in an open position, illustrating a plurality of LEDs from theproximal to the distal end of the staple cartridge, and on either sideof the cartridge deck.

FIG. 98A illustrates an embodiment wherein the tissue compensator isremovably attached to the anvil portion of the end effector;

FIG. 98B illustrates a detail view of a portion of the tissuecompensator shown in FIG. 98A;

FIG. 99 illustrates various example embodiments that use the layer ofconductive elements and conductive elements in the staple cartridge todetect the distance between the anvil and the upper surface of thestaple cartridge;

FIGS. 100A and 100B illustrate an embodiment of the tissue compensatorcomprising a layer of conductive elements in operation;

FIGS. 101A and 101B illustrate an embodiment of an end effectorcomprising a tissue compensator further comprising conductors embeddedwithin;

FIGS. 102A and 102B illustrate an embodiment of an end effectorcomprising a tissue compensator further comprising conductors embeddedtherein;

FIG. 103 illustrates an embodiment of a staple cartridge and a tissuecompensator wherein the staple cartridge provides power to theconductive elements that comprise the tissue compensator;

FIGS. 104A and 104B illustrate an embodiment of a staple cartridge and atissue compensator wherein the staple cartridge provides power to theconductive elements that comprise the tissue compensator;

FIGS. 105A and 105B illustrate an embodiment of an end effectorcomprising position sensing elements and a tissue compensator;

FIGS. 106A and 106B illustrate an embodiment of an end effectorcomprising position sensing elements and a tissue compensator;

FIGS. 107A and 107B illustrate an embodiment of a staple cartridge and atissue compensator that is operable to indicate the position of acutting member or knife bar;

FIG. 108 illustrates one embodiment of an end effector comprising amagnet and a Hall effect sensor wherein the detected magnetic field canbe used to identify a staple cartridge;

FIG. 109 illustrates on embodiment of an end effector comprising amagnet and a Hall effect sensor wherein the detected magnetic field canbe used to identify a staple cartridge;

FIG. 110 illustrates a graph of the voltage detected by a Hall effectsensor located in the distal tip of a staple cartridge, such as isillustrated in FIGS. 108 and 109, in response to the distance or gapbetween a magnet located in the anvil and the Hall effect sensor in thestaple cartridge, such as illustrated in FIGS. 108 and 109;

FIG. 111 illustrates one embodiment of the housing of the surgicalinstrument, comprising a display;

FIG. 112 illustrates one embodiment of a staple retainer comprising amagnet;

FIGS. 113A and 113B illustrate one embodiment of an end effectorcomprising a sensor for identifying staple cartridges of differenttypes;

FIG. 114 is a partial view of an end effector with sensor powerconductors for transferring power and data signals between the connectedcomponents of the surgical instrument according to one embodiment.

FIG. 115 is a partial view of the end effector shown in FIG. 114 showingsensors and/or electronic components located in an end effector.

FIG. 116 is a block diagram of a surgical instrument electronicsubsystem comprising a short circuit protection circuit for the sensorsand/or electronic components according to one embodiment.

FIG. 117 is a short circuit protection circuit comprising asupplementary power supply circuit 7014 coupled to a main power supplycircuit, according to one embodiment.

FIG. 118 is a block diagram of a surgical instrument electronicsubsystem comprising a sample rate monitor to provide power reduction bylimiting sample rates and/or duty cycle of the sensor components whenthe surgical instrument is in a non-sensing state, according to oneembodiment.

FIG. 119 is a block diagram of a surgical instrument electronicsubsystem comprising an over current/voltage protection circuit forsensors and/or electronic components of a surgical instrument, accordingto one embodiment.

FIG. 120 is an over current/voltage protection circuit for sensors andelectronic components for a surgical instrument, according to oneembodiment.

FIG. 121 is a block diagram of a surgical instrument electronicsubsystem with a reverse polarity protection circuit for sensors and/orelectronic components according to one embodiment.

FIG. 122 is a reverse polarity protection circuit for sensors and/orelectronic components for a surgical instrument according to oneembodiment.

FIG. 123 is a block diagram of a surgical instrument electronicsubsystem with power reduction utilizing a sleep mode monitor forsensors and/or electronic components according to one embodiment.

FIG. 124 is a block diagram of a surgical instrument electronicsubsystem comprising a temporary power loss circuit to provideprotection against intermittent power loss for sensors and/or electroniccomponents in modular surgical instruments.

FIG. 125 illustrates one embodiment of a temporary power loss circuitimplemented as a hardware circuit.

FIG. 126A illustrates a perspective view of one embodiment of an endeffector comprising a magnet and a Hall effect sensor in communicationwith a processor;

FIG. 126B illustrates a sideways cross-sectional view of one embodimentof an end effector comprising a magnet and a Hall effect sensor incommunication with processor;

FIG. 127 illustrates one embodiment of the operable dimensions thatrelate to the operation of the Hall effect sensor;

FIG. 128A illustrates an external side view of an embodiment of a staplecartridge;

FIG. 128B illustrates various dimensions possible between the lowersurface of the push-off lug and the top of the Hall effect sensor;

FIG. 128C illustrates an external side view of an embodiment of a staplecartridge;

FIG. 128D illustrates various dimensions possible between the lowersurface of the push-off lug and the upper surface of the staplecartridge above the Hall effect sensor;

FIG. 129A further illustrates a front-end cross-sectional view 10054 ofthe anvil 10002 and the central axis point of the anvil;

FIG. 129B is a cross sectional view of a magnet shown in FIG. 129A;

FIGS. 130A-130E illustrate one embodiment of an end effector thatcomprises a magnet where FIG. 130A illustrates a front-endcross-sectional view of the end effector, FIG. 130B illustrates afront-end cutaway view of the anvil and the magnet in situ, FIG. 130Cillustrates a perspective cutaway view of the anvil and the magnet, FIG.130D illustrates a side cutaway view of the anvil and the magnet, andFIG. 130E illustrates a top cutaway view of the anvil and the magnet;

FIGS. 131A-131E illustrate another embodiment of an end effector thatcomprises a magnet where FIG. 131A illustrates a front-endcross-sectional view of the end effector, FIG. 131B illustrates afront-end cutaway view of the anvil and the magnet, in situ, FIG. 131Cillustrates a perspective cutaway view of the anvil and the magnet, FIG.131D illustrates a side cutaway view of the anvil and the magnet, andFIG. 131E illustrates a top cutaway view of the anvil and magnet;

FIG. 132 illustrates contact points between the anvil and either thestaple cartridge and/or the elongated channel;

FIGS. 133A and 133B illustrate one embodiment of an end effector that isoperable to use conductive surfaces at the distal contact point tocreate an electrical connection;

FIGS. 134A-134C illustrate one embodiment of an end effector that isoperable to use conductive surfaces to form an electrical connectionwhere FIG. 134A illustrates an end effector comprising an anvil, anelongated channel, and a staple cartridge, FIG. 134B illustrates theinside surface of the anvil further comprising first conductive surfaceslocated distally from the staple-forming indents, and FIG. 134Cillustrates the staple cartridge comprising a cartridge body and firstconductive surfaces located such that they can come into contact with asecond conductive surface located on the staple cartridge;

FIGS. 135A and 135B illustrate one embodiment of an end effector that isoperable to use conductive surfaces to form an electrical connectionwhere FIG. 135A illustrates an end effector comprising an anvil, anelongated channel, and a staple cartridge and FIG. 135B is a close-upview of the staple cartridge illustrating the first conductive surfacelocated such that it can come into contact with second conductivesurfaces;

FIGS. 136A and 136B illustrate one embodiment of an end effector that isoperable to use conductive surfaces to form an electrical connectionwhere FIG. 136A illustrates an end effector comprising an anvil, anelongated channel, and a staple cartridge and FIG. 136B is a close-upview of the staple cartridge illustrating the anvil further comprising amagnet and an inside surface, which further comprises a number ofstaple-forming indents;

FIGS. 137A-137C illustrate one embodiment of an end effector that isoperable to use the proximal contact point to form an electricalconnection where FIG. 137A illustrates the end effector, which comprisesan anvil, an elongated channel, and a staple cartridge, FIG. 137B is aclose-up view of a pin as it rests within an aperture defined in theelongated channel for that purpose, and FIG. 137C illustrates analternate embodiment, with an alternate location for a second conductivesurface on the surface of the aperture;

FIG. 138 illustrates one embodiment of an end effector with a distalsensor plug;

FIG. 139A illustrates the end effector shown in FIG. 138 with the anvilin an open position;

FIG. 139B illustrates a cross-sectional view of the end effector shownin FIG. 139A with the anvil in an open position;

FIG. 139C illustrates the end effector shown in FIG. 138 with the anvilin a closed position;

FIG. 139D illustrates a cross sectional view of the end effector shownin FIG. 139C with the anvil in a closed position;

FIG. 140 provides a close-up view of the cross section of the distal endof the end effector;

FIG. 141 illustrates a close-up top view of the staple cartridge thatcomprises a distal sensor plug;

FIG. 142A is a perspective view of the underside of a staple cartridgethat comprises a distal sensor plug;

FIG. 142B illustrates a cross sectional view of the distal end of thestaple cartridge;

FIGS. 143A-143C illustrate one embodiment of a staple cartridge thatcomprises a flex cable connected to a Hall effect sensor and processorwhere FIG. 143A is an exploded view of the staple cartridge, FIG. 143Billustrates the assembly of the staple cartridge and the flex cable ingreater detail, and FIG. 143C illustrates a cross sectional view of thestaple cartridge to illustrate the placement of the Hall effect sensor,processor, and conductive coupling within the distal end of the staplecartridge, in accordance with the present embodiment;

FIG. 144A-144F illustrate one embodiment of a staple cartridge thatcomprises a flex cable connected to a Hall effect sensor and a processorwhere FIG. 144A is an exploded view of the staple cartridge, FIG. 144Billustrates the assembly of the staple cartridge, FIG. 144C illustratesthe underside of an assembled staple cartridge, and also illustrates theflex cable in greater detail, FIG. 144D illustrates a cross sectionalview of the staple cartridge to illustrate the placement of the Halleffect sensor, processor, and conductive coupling, FIG. 144E illustratesthe underside of the staple cartridge without the cartridge tray andincluding the wedge sled, in its most distal position, and FIG. 144Fillustrates the staple cartridge without the cartridge tray in order toillustrate a possible placement for the cable traces;

FIG. 145A and 145B illustrates one embodiment of a staple cartridge thatcomprises a flex cable, a Hall effect sensor, and a processor where FIG.145A is an exploded view of the staple cartridge and FIG. 145Billustrates the assembly of the staple cartridge and the flex cable ingreater detail;

FIG. 146A illustrates a perspective view of an end effector coupled to ashaft assembly;

FIG. 146B illustrates a perspective view of an underside of the endeffector and shaft assembly shown in FIG. 146A;

FIG. 146C illustrates the end effector shown in FIGS. 146A and 146B witha flex cable and without the shaft assembly;

FIGS. 146D and 146E illustrate an elongated channel portion of the endeffector shown in FIGS. 146A and 146B without the anvil or the staplecartridge, to illustrate how the flex cable shown in FIG. 146C can beseated within the elongated channel;

FIG. 146F illustrates the flex cable, shown in FIGS. 146C-146E, alone;

FIG. 147 illustrates a close up view of the elongated channel shown inFIGS. 146D and 146E with a staple cartridge coupled thereto;

FIGS. 148A-148D further illustrate one embodiment of a staple cartridgeoperative with the present embodiment of an end effector where FIG. 148Aillustrates a close up view of the proximal end of the staple cartridge,FIG. 148B illustrates a close-up view of the distal end of the staplecartridge, with a space for a distal sensor plug, FIG. 148C furtherillustrates the distal sensor plug, and FIG. 148D illustrates theproximal-facing side of the distal sensor plug;

FIGS. 149A and 149B illustrate one embodiment of a distal sensor plugwhere FIG. 149A illustrates a cutaway view of the distal sensor plug andFIG. 149B further illustrates the Hall effect sensor and the processoroperatively coupled to the flex board such that they are capable ofcommunicating;

FIG. 150 illustrates an embodiment of an end effector with a flex cableoperable to provide power to sensors and electronics in the distal tipof the anvil portion;

FIGS. 151A-151C illustrate the operation of the articulation joint andflex cable of the end effector where FIG. 151A illustrates a top view ofthe end effector with the end effector pivoted −45 degrees with respectto the shaft assembly, FIG. 151B illustrates a top view of the endeffector, and FIG. 151C illustrates a top view of the end effector withthe end effector pivoted +45 degrees with respect to the shaft assembly;

FIG. 152 illustrates cross-sectional view of the distal tip of anembodiment of an anvil with sensors and electronics; and

FIG. 153 illustrates a cutaway view of the distal tip of the anvil.

DESCRIPTION

Certain example embodiments will now be described to provide an overallunderstanding of the principles of the structure, function, manufacture,and use of the devices and methods disclosed herein. One or moreexamples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting example embodiments. The featuresillustrated or described in connection with one example embodiment maybe combined with the features of other embodiments. Such modificationsand variations are intended to be included within the scope of thepresent embodiment of the invention.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” or “an embodiment”, or the like, meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodiment.Thus, appearances of the phrases “in various embodiments,” “in someembodiments,” “in one embodiment”, or “in an embodiment”, or the like,in places throughout the specification are not necessarily all referringto the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more embodiments. Thus, the particular features, structures, orcharacteristics illustrated or described in connection with oneembodiment may be combined, in whole or in part, with the featuresstructures, or characteristics of one or more other embodiments withoutlimitation. Such modifications and variations are intended to beincluded within the scope of the present embodiment of the invention.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical,” “horizontal,” “up,” and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various example devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIGS. 1-6 depict a motor-driven surgical cutting and fasteninginstrument 10 that may or may not be reused. In the illustratedembodiment, the instrument 10 includes a housing 12 that comprises ahandle 14 that is configured to be grasped, manipulated and actuated bythe clinician. The housing 12 is configured for operable attachment toan interchangeable shaft assembly 200 that has a surgical end effector300 operably coupled thereto that is configured to perform one or moresurgical tasks or procedures. As the present Detailed Descriptionproceeds, it will be understood that the various unique and novelarrangements of the various forms of interchangeable shaft assembliesdisclosed herein may also be effectively employed in connection withrobotically-controlled surgical systems. Thus, the term “housing” mayalso encompass a housing or similar portion of a robotic system thathouses or otherwise operably supports at least one drive system that isconfigured to generate and apply at least one control motion which couldbe used to actuate the interchangeable shaft assemblies disclosed hereinand their respective equivalents. The term “frame” may refer to aportion of a handheld surgical instrument. The term “frame” may alsorepresent a portion of a robotically controlled surgical instrumentand/or a portion of the robotic system that may be used to operablycontrol a surgical instrument. For example, the interchangeable shaftassemblies disclosed herein may be employed with various roboticsystems, instruments, components and methods disclosed in U.S. patentapplication Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTSWITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. PatentApplication Publication No. US 2012/0298719. U.S. patent applicationSer. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent ApplicationPublication No. US 2012/0298719, is incorporated by reference herein inits entirety.

The housing 12 depicted in FIGS. 1-3 is shown in connection with aninterchangeable shaft assembly 200 that includes an end effector 300that comprises a surgical cutting and fastening device that isconfigured to operably support a surgical staple cartridge 304 therein.The housing 12 may be configured for use in connection withinterchangeable shaft assemblies that include end effectors that areadapted to support different sizes and types of staple cartridges, havedifferent shaft lengths, sizes, and types, etc. In addition, the housing12 may also be effectively employed with a variety of otherinterchangeable shaft assemblies including those assemblies that areconfigured to apply other motions and forms of energy such as, forexample, radio frequency (RF) energy, ultrasonic energy and/or motion toend effector arrangements adapted for use in connection with varioussurgical applications and procedures. Furthermore, the end effectors,shaft assemblies, handles, surgical instruments, and/or surgicalinstrument systems can utilize any suitable fastener, or fasteners, tofasten tissue. For instance, a fastener cartridge comprising a pluralityof fasteners removably stored therein can be removably inserted intoand/or attached to the end effector of a shaft assembly.

FIG. 1 illustrates the surgical instrument 10 with an interchangeableshaft assembly 200 operably coupled thereto. FIGS. 2 and 3 illustrateattachment of the interchangeable shaft assembly 200 to the housing 12or handle 14. As shown in FIG. 4, the handle 14 may comprise a pair ofinterconnectable handle housing segments 16 and 18 that may beinterconnected by screws, snap features, adhesive, etc. In theillustrated arrangement, the handle housing segments 16, 18 cooperate toform a pistol grip portion 19 that can be gripped and manipulated by theclinician. As will be discussed in further detail below, the handle 14operably supports a plurality of drive systems therein that areconfigured to generate and apply various control motions tocorresponding portions of the interchangeable shaft assembly that isoperably attached thereto.

Referring now to FIG. 4, the handle 14 may further include a frame 20that operably supports a plurality of drive systems. For example, theframe 20 can operably support a “first” or closure drive system,generally designated as 30, which may be employed to apply closing andopening motions to the interchangeable shaft assembly 200 that isoperably attached or coupled thereto. In at least one form, the closuredrive system 30 may include an actuator in the form of a closure trigger32 that is pivotally supported by the frame 20. More specifically, asillustrated in FIG. 4, the closure trigger 32 is pivotally coupled tothe housing 14 by a pin 33. Such arrangement enables the closure trigger32 to be manipulated by a clinician such that when the clinician gripsthe pistol grip portion 19 of the handle 14, the closure trigger 32 maybe easily pivoted from a starting or “unactuated” position to an“actuated” position and more particularly to a fully compressed or fullyactuated position. The closure trigger 32 may be biased into theunactuated position by spring or other biasing arrangement (not shown).In various forms, the closure drive system 30 further includes a closurelinkage assembly 34 that is pivotally coupled to the closure trigger 32.As shown in FIG. 4, the closure linkage assembly 34 may include a firstclosure link 36 and a second closure link 38 that are pivotally coupledto the closure trigger 32 by a pin 35. The second closure link 38 mayalso be referred to herein as an “attachment member” and include atransverse attachment pin 37.

Still referring to FIG. 4, it can be observed that the first closurelink 36 may have a locking wall or end 39 thereon that is configured tocooperate with a closure release assembly 60 that is pivotally coupledto the frame 20. In at least one form, the closure release assembly 60may comprise a release button assembly 62 that has a distally protrudinglocking pawl 64 formed thereon. The release button assembly 62 may bepivoted in a counterclockwise direction by a release spring (not shown).As the clinician depresses the closure trigger 32 from its unactuatedposition towards the pistol grip portion 19 of the handle 14, the firstclosure link 36 pivots upward to a point wherein the locking pawl 64drops into retaining engagement with the locking wall 39 on the firstclosure link 36 thereby preventing the closure trigger 32 from returningto the unactuated position. See FIG. 18. Thus, the closure releaseassembly 60 serves to lock the closure trigger 32 in the fully actuatedposition. When the clinician desires to unlock the closure trigger 32 topermit it to be biased to the unactuated position, the clinician simplypivots the closure release button assembly 62 such that the locking pawl64 is moved out of engagement with the locking wall 39 on the firstclosure link 36. When the locking pawl 64 has been moved out ofengagement with the first closure link 36, the closure trigger 32 maypivot back to the unactuated position. Other closure trigger locking andrelease arrangements may also be employed.

Further to the above, FIGS. 13-15 illustrate the closure trigger 32 inits unactuated position which is associated with an open, or unclamped,configuration of the shaft assembly 200 in which tissue can bepositioned between the jaws of the shaft assembly 200. FIGS. 16-18illustrate the closure trigger 32 in its actuated position which isassociated with a closed, or clamped, configuration of the shaftassembly 200 in which tissue is clamped between the jaws of the shaftassembly 200. Upon comparing FIGS. 14 and 17, the reader will appreciatethat, when the closure trigger 32 is moved from its unactuated position(FIG. 14) to its actuated position (FIG. 17), the closure release button62 is pivoted between a first position (FIG. 14) and a second position(FIG. 17). The rotation of the closure release button 62 can be referredto as being an upward rotation; however, at least a portion of theclosure release button 62 is being rotated toward the circuit board 100.Referring to FIG. 4, the closure release button 62 can include an arm 61extending therefrom and a magnetic element 63, such as a permanentmagnet, for example, mounted to the arm 61. When the closure releasebutton 62 is rotated from its first position to its second position, themagnetic element 63 can move toward the circuit board 100. The circuitboard 100 can include at least one sensor configured to detect themovement of the magnetic element 63. In at least one embodiment, a Halleffect sensor 65, for example, can be mounted to the bottom surface ofthe circuit board 100. The Hall effect sensor 65 can be configured todetect changes in a magnetic field surrounding the Hall effect sensor 65caused by the movement of the magnetic element 63. The Hall effectsensor 65 can be in signal communication with a microcontroller 1500(FIG. 19), for example, which can determine whether the closure releasebutton 62 is in its first position, which is associated with theunactuated position of the closure trigger 32 and the open configurationof the end effector, its second position, which is associated with theactuated position of the closure trigger 32 and the closed configurationof the end effector, and/or any position between the first position andthe second position.

In at least one form, the handle 14 and the frame 20 may operablysupport another drive system referred to herein as a firing drive system80 that is configured to apply firing motions to corresponding portionsof the interchangeable shaft assembly attached thereto. The firing drivesystem may 80 also be referred to herein as a “second drive system”. Thefiring drive system 80 may employ an electric motor 82, located in thepistol grip portion 19 of the handle 14. In various forms, the motor 82may be a DC brushed driving motor having a maximum rotation of,approximately, 25,000 RPM, for example. In other arrangements, the motormay include a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. The motor 82 may bepowered by a power source 90 that in one form may comprise a removablepower pack 92. As shown in FIG. 4, for example, the power pack 92 maycomprise a proximal housing portion 94 that is configured for attachmentto a distal housing portion 96. The proximal housing portion 94 and thedistal housing portion 96 are configured to operably support a pluralityof batteries 98 therein. Batteries 98 may each comprise, for example, aLithium Ion (“LI”) or other suitable battery. The distal housing portion96 is configured for removable operable attachment to a control circuitboard assembly 100 which is also operably coupled to the motor 82. Anumber of batteries 98 may be connected in series may be used as thepower source for the surgical instrument 10. In addition, the powersource 90 may be replaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 82 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 84 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 122 on alongitudinally-movable drive member 120. In use, a voltage polarityprovided by the power source 90 can operate the electric motor 82 in aclockwise direction wherein the voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor 82 in a counter-clockwise direction. When the electric motor 82 isrotated in one direction, the drive member 120 will be axially driven inthe distal direction “DD”. When the motor 82 is driven in the oppositerotary direction, the drive member 120 will be axially driven in aproximal direction “PD”. The handle 14 can include a switch which can beconfigured to reverse the polarity applied to the electric motor 82 bythe power source 90. As with the other forms described herein, thehandle 14 can also include a sensor that is configured to detect theposition of the drive member 120 and/or the direction in which the drivemember 120 is being moved.

Actuation of the motor 82 can be controlled by a firing trigger 130 thatis pivotally supported on the handle 14. The firing trigger 130 may bepivoted between an unactuated position and an actuated position. Thefiring trigger 130 may be biased into the unactuated position by aspring 132 or other biasing arrangement such that when the clinicianreleases the firing trigger 130, it may be pivoted or otherwise returnedto the unactuated position by the spring 132 or biasing arrangement. Inat least one form, the firing trigger 130 can be positioned “outboard”of the closure trigger 32 as was discussed above. In at least one form,a firing trigger safety button 134 may be pivotally mounted to theclosure trigger 32 by pin 35. The safety button 134 may be positionedbetween the firing trigger 130 and the closure trigger 32 and have apivot arm 136 protruding therefrom. See FIG. 4. When the closure trigger32 is in the unactuated position, the safety button 134 is contained inthe handle 14 where the clinician cannot readily access it and move itbetween a safety position preventing actuation of the firing trigger 130and a firing position wherein the firing trigger 130 may be fired. Asthe clinician depresses the closure trigger 32, the safety button 134and the firing trigger 130 pivot down wherein they can then bemanipulated by the clinician.

As discussed above, the handle 14 can include a closure trigger 32 and afiring trigger 130. Referring to FIGS. 14-18A, the firing trigger 130can be pivotably mounted to the closure trigger 32. The closure trigger32 can include an arm 31 extending therefrom and the firing trigger 130can be pivotably mounted to the arm 31 about a pivot pin 33. When theclosure trigger 32 is moved from its unactuated position (FIG. 14) toits actuated position (FIG. 17), the firing trigger 130 can descenddownwardly, as outlined above. After the safety button 134 has beenmoved to its firing position, referring primarily to FIG. 18A, thefiring trigger 130 can be depressed to operate the motor of the surgicalinstrument firing system. In various instances, the handle 14 caninclude a tracking system, such as system 800, for example, configuredto determine the position of the closure trigger 32 and/or the positionof the firing trigger 130. With primary reference to FIGS. 14, 17, and18A, the tracking system 800 can include a magnetic element, such aspermanent magnet 802, for example, which is mounted to an arm 801extending from the firing trigger 130. The tracking system 800 cancomprise one or more sensors, such as a first Hall effect sensor 803 anda second Hall effect sensor 804, for example, which can be configured totrack the position of the magnet 802. Upon comparing FIGS. 14 and 17,the reader will appreciate that, when the closure trigger 32 is movedfrom its unactuated position to its actuated position, the magnet 802can move between a first position adjacent the first Hall effect sensor803 and a second position adjacent the second Hall effect sensor 804.Upon comparing FIGS. 17 and 18A, the reader will further appreciatethat, when the firing trigger 130 is moved from an unfired position(FIG. 17) to a fired position (FIG. 18A), the magnet 802 can moverelative to the second Hall effect sensor 804. The sensors 803 and 804can track the movement of the magnet 802 and can be in signalcommunication with a microcontroller on the circuit board 100. With datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the closure trigger 32 is in its unactuated position,its actuated position, or a position therebetween. Similarly, with datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the firing trigger 130 is in its unfired position, itsfully fired position, or a position therebetween.

As indicated above, in at least one form, the longitudinally movabledrive member 120 has a rack of teeth 122 formed thereon for meshingengagement with a corresponding drive gear 86 of the gear reducerassembly 84. At least one form also includes a manually-actuatable“bailout” assembly 140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 120 should themotor 82 become disabled. The bailout assembly 140 may include a leveror bailout handle assembly 142 that is configured to be manually pivotedinto ratcheting engagement with teeth 124 also provided in the drivemember 120. Thus, the clinician can manually retract the drive member120 by using the bailout handle assembly 142 to ratchet the drive member120 in the proximal direction “PD”. U.S. Patent Application PublicationNo. US 2010/0089970 discloses bailout arrangements and other components,arrangements and systems that may also be employed with the variousinstruments disclosed herein. U.S. patent application Ser. No.12/249,117, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUSWITH MANUALLY RETRACTABLE FIRING SYSTEM, now U.S. Patent ApplicationPublication No. 2010/0089970, is hereby incorporated by reference in itsentirety.

Turning now to FIGS. 1 and 7, the interchangeable shaft assembly 200includes a surgical end effector 300 that comprises an elongated channel302 that is configured to operably support a staple cartridge 304therein. The end effector 300 may further include an anvil 306 that ispivotally supported relative to the elongated channel 302. Theinterchangeable shaft assembly 200 may further include an articulationjoint 270 and an articulation lock 350 (FIG. 8) which can be configuredto releasably hold the end effector 300 in a desired position relativeto a shaft axis SA-SA. Details regarding the construction and operationof the end effector 300, the articulation joint 270 and the articulationlock 350 are set forth in U.S. patent application Ser. No. 13/803,086,filed Mar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENTCOMPRISING AN ARTICULATION LOCK. The entire disclosure of U.S. patentapplication Ser. No. 13/803,086, filed Mar. 14, 2013, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK ishereby incorporated by reference herein. As shown in FIGS. 7 and 8, theinterchangeable shaft assembly 200 can further include a proximalhousing or nozzle 201 comprised of nozzle portions 202 and 203. Theinterchangeable shaft assembly 200 can further include a closure tube260 which can be utilized to close and/or open the anvil 306 of the endeffector 300. Primarily referring now to FIGS. 8 and 9, the shaftassembly 200 can include a spine 210 which can be configured to fixablysupport a shaft frame portion 212 of the articulation lock 350. See FIG.8. The spine 210 can be configured to, one, slidably support a firingmember 220 therein and, two, slidably support the closure tube 260 whichextends around the spine 210. The spine 210 can also be configured toslidably support a proximal articulation driver 230. The articulationdriver 230 has a distal end 231 that is configured to operably engagethe articulation lock 350. The articulation lock 350 interfaces with anarticulation frame 352 that is adapted to operably engage a drive pin(not shown) on the end effector frame (not shown). As indicated above,further details regarding the operation of the articulation lock 350 andthe articulation frame may be found in U.S. patent application Ser. No.13/803,086. In various circumstances, the spine 210 can comprise aproximal end 211 which is rotatably supported in a chassis 240. In onearrangement, for example, the proximal end 211 of the spine 210 has athread 214 formed thereon for threaded attachment to a spine bearing 216configured to be supported within the chassis 240. See FIG. 7. Such anarrangement facilitates rotatable attachment of the spine 210 to thechassis 240 such that the spine 210 may be selectively rotated about ashaft axis SA-SA relative to the chassis 240.

Referring primarily to FIG. 7, the interchangeable shaft assembly 200includes a closure shuttle 250 that is slidably supported within thechassis 240 such that it may be axially moved relative thereto. As shownin FIGS. 3 and 7, the closure shuttle 250 includes a pair ofproximally-protruding hooks 252 that are configured for attachment tothe attachment pin 37 that is attached to the second closure link 38 aswill be discussed in further detail below. A proximal end 261 of theclosure tube 260 is coupled to the closure shuttle 250 for relativerotation thereto. For example, a U shaped connector 263 is inserted intoan annular slot 262 in the proximal end 261 of the closure tube 260 andis retained within vertical slots 253 in the closure shuttle 250. SeeFIG. 7. Such an arrangement serves to attach the closure tube 260 to theclosure shuttle 250 for axial travel therewith while enabling theclosure tube 260 to rotate relative to the closure shuttle 250 about theshaft axis SA-SA. A closure spring 268 is journaled on the closure tube260 and serves to bias the closure tube 260 in the proximal direction“PD” which can serve to pivot the closure trigger into the unactuatedposition when the shaft assembly is operably coupled to the handle 14.

In at least one form, the interchangeable shaft assembly 200 may furtherinclude an articulation joint 270. Other interchangeable shaftassemblies, however, may not be capable of articulation. As shown inFIG. 7, for example, the articulation joint 270 includes a double pivotclosure sleeve assembly 271. According to various forms, the doublepivot closure sleeve assembly 271 includes an end effector closuresleeve assembly 272 having upper and lower distally projecting tangs273, 274. An end effector closure sleeve assembly 272 includes ahorseshoe aperture 275 and a tab 276 for engaging an opening tab on theanvil 306 in the various manners described in U.S. patent applicationSer. No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK which has beenincorporated by reference herein. As described in further detailtherein, the horseshoe aperture 275 and tab 276 engage a tab on theanvil when the anvil 306 is opened. An upper double pivot link 277includes upwardly projecting distal and proximal pivot pins that engagerespectively an upper distal pin hole in the upper proximally projectingtang 273 and an upper proximal pin hole in an upper distally projectingtang 264 on the closure tube 260. A lower double pivot link 278 includesupwardly projecting distal and proximal pivot pins that engagerespectively a lower distal pin hole in the lower proximally projectingtang 274 and a lower proximal pin hole in the lower distally projectingtang 265. See also FIG. 8.

In use, the closure tube 260 is translated distally (direction “DD”) toclose the anvil 306, for example, in response to the actuation of theclosure trigger 32. The anvil 306 is closed by distally translating theclosure tube 260 and thus the shaft closure sleeve assembly 272, causingit to strike a proximal surface on the anvil 360 in the manner describedin the aforementioned reference U.S. patent application Ser. No.13/803,086. As was also described in detail in that reference, the anvil306 is opened by proximally translating the closure tube 260 and theshaft closure sleeve assembly 272, causing tab 276 and the horseshoeaperture 275 to contact and push against the anvil tab to lift the anvil306. In the anvil-open position, the shaft closure tube 260 is moved toits proximal position.

As indicated above, the surgical instrument 10 may further include anarticulation lock 350 of the types and construction described in furtherdetail in U.S. patent application Ser. No. 13/803,086 which can beconfigured and operated to selectively lock the end effector 300 inposition. Such arrangement enables the end effector 300 to be rotated,or articulated, relative to the shaft closure tube 260 when thearticulation lock 350 is in its unlocked state. In such an unlockedstate, the end effector 300 can be positioned and pushed against softtissue and/or bone, for example, surrounding the surgical site withinthe patient in order to cause the end effector 300 to articulaterelative to the closure tube 260. The end effector 300 may also bearticulated relative to the closure tube 260 by an articulation driver230.

As was also indicated above, the interchangeable shaft assembly 200further includes a firing member 220 that is supported for axial travelwithin the shaft spine 210. The firing member 220 includes anintermediate firing shaft portion 222 that is configured for attachmentto a distal cutting portion or knife bar 280. The firing member 220 mayalso be referred to herein as a “second shaft” and/or a “second shaftassembly”. As shown in FIGS. 8 and 9, the intermediate firing shaftportion 222 may include a longitudinal slot 223 in the distal endthereof which can be configured to receive a tab 284 on the proximal end282 of the distal knife bar 280. The longitudinal slot 223 and theproximal end 282 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint 286. The slip joint 286 canpermit the intermediate firing shaft portion 222 of the firing drive 220to be moved to articulate the end effector 300 without moving, or atleast substantially moving, the knife bar 280. Once the end effector 300has been suitably oriented, the intermediate firing shaft portion 222can be advanced distally until a proximal sidewall of the longitudinalslot 223 comes into contact with the tab 284 in order to advance theknife bar 280 and fire the staple cartridge positioned within thechannel 302 As can be further seen in FIGS. 8 and 9, the shaft spine 210has an elongate opening or window 213 therein to facilitate assembly andinsertion of the intermediate firing shaft portion 222 into the shaftframe 210. Once the intermediate firing shaft portion 222 has beeninserted therein, a top frame segment 215 may be engaged with the shaftframe 212 to enclose the intermediate firing shaft portion 222 and knifebar 280 therein. Further description of the operation of the firingmember 220 may be found in U.S. patent application Ser. No. 13/803,086.

Further to the above, the shaft assembly 200 can include a clutchassembly 400 which can be configured to selectively and releasablycouple the articulation driver 230 to the firing member 220. In oneform, the clutch assembly 400 includes a lock collar, or sleeve 402,positioned around the firing member 220 wherein the lock sleeve 402 canbe rotated between an engaged position in which the lock sleeve 402couples the articulation driver 360 to the firing member 220 and adisengaged position in which the articulation driver 360 is not operablycoupled to the firing member 220. When lock sleeve 402 is in its engagedposition, distal movement of the firing member 220 can move thearticulation driver 360 distally and, correspondingly, proximal movementof the firing member 220 can move the articulation driver 230proximally. When lock sleeve 402 is in its disengaged position, movementof the firing member 220 is not transmitted to the articulation driver230 and, as a result, the firing member 220 can move independently ofthe articulation driver 230. In various circumstances, the articulationdriver 230 can be held in position by the articulation lock 350 when thearticulation driver 230 is not being moved in the proximal or distaldirections by the firing member 220.

Referring primarily to FIG. 9, the lock sleeve 402 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 403 defined therein configured to receive thefiring member 220. The lock sleeve 402 can comprisediametrically-opposed, inwardly-facing lock protrusions 404 and anoutwardly-facing lock member 406. The lock protrusions 404 can beconfigured to be selectively engaged with the firing member 220. Moreparticularly, when the lock sleeve 402 is in its engaged position, thelock protrusions 404 are positioned within a drive notch 224 defined inthe firing member 220 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member 220 to the locksleeve 402. When the lock sleeve 402 is in its engaged position, thesecond lock member 406 is received within a drive notch 232 defined inthe articulation driver 230 such that the distal pushing force and/orthe proximal pulling force applied to the lock sleeve 402 can betransmitted to the articulation driver 230. In effect, the firing member220, the lock sleeve 402, and the articulation driver 230 will movetogether when the lock sleeve 402 is in its engaged position. On theother hand, when the lock sleeve 402 is in its disengaged position, thelock protrusions 404 may not be positioned within the drive notch 224 ofthe firing member 220 and, as a result, a distal pushing force and/or aproximal pulling force may not be transmitted from the firing member 220to the lock sleeve 402. Correspondingly, the distal pushing force and/orthe proximal pulling force may not be transmitted to the articulationdriver 230. In such circumstances, the firing member 220 can be slidproximally and/or distally relative to the lock sleeve 402 and theproximal articulation driver 230.

As shown in FIGS. 8-12, the shaft assembly 200 further includes a switchdrum 500 that is rotatably received on the closure tube 260. The switchdrum 500 comprises a hollow shaft segment 502 that has a shaft boss 504formed thereon for receive an outwardly protruding actuation pin 410therein. In various circumstances, the actuation pin 410 extends througha slot 267 into a longitudinal slot 408 provided in the lock sleeve 402to facilitate axial movement of the lock sleeve 402 when it is engagedwith the articulation driver 230. A rotary torsion spring 420 isconfigured to engage the boss 504 on the switch drum 500 and a portionof the nozzle housing 203 as shown in FIG. 10 to apply a biasing forceto the switch drum 500. The switch drum 500 can further comprise atleast partially circumferential openings 506 defined therein which,referring to FIGS. 5 and 6, can be configured to receive circumferentialmounts 204, 205 extending from the nozzle halves 202, 203 and permitrelative rotation, but not translation, between the switch drum 500 andthe proximal nozzle 201. As shown in those Figures, the mounts 204 and205 also extend through openings 266 in the closure tube 260 to beseated in recesses 211 in the shaft spine 210. However, rotation of thenozzle 201 to a point where the mounts 204, 205 reach the end of theirrespective slots 506 in the switch drum 500 will result in rotation ofthe switch drum 500 about the shaft axis SA-SA. Rotation of the switchdrum 500 will ultimately result in the rotation of eth actuation pin 410and the lock sleeve 402 between its engaged and disengaged positions.Thus, in essence, the nozzle 201 may be employed to operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086.

As also illustrated in FIGS. 8-12, the shaft assembly 200 can comprise aslip ring assembly 600 which can be configured to conduct electricalpower to and/or from the end effector 300 and/or communicate signals toand/or from the end effector 300, for example. The slip ring assembly600 can comprise a proximal connector flange 604 mounted to a chassisflange 242 extending from the chassis 240 and a distal connector flange601 positioned within a slot defined in the shaft housings 202, 203. Theproximal connector flange 604 can comprise a first face and the distalconnector flange 601 can comprise a second face which is positionedadjacent to and movable relative to the first face. The distal connectorflange 601 can rotate relative to the proximal connector flange 604about the shaft axis SA-SA. The proximal connector flange 604 cancomprise a plurality of concentric, or at least substantiallyconcentric, conductors 602 defined in the first face thereof. Aconnector 607 can be mounted on the proximal side of the connectorflange 601 and may have a plurality of contacts (not shown) wherein eachcontact corresponds to and is in electrical contact with one of theconductors 602. Such an arrangement permits relative rotation betweenthe proximal connector flange 604 and the distal connector flange 601while maintaining electrical contact therebetween. The proximalconnector flange 604 can include an electrical connector 606 which canplace the conductors 602 in signal communication with a shaft circuitboard 610 mounted to the shaft chassis 240, for example. In at least oneinstance, a wiring harness comprising a plurality of conductors canextend between the electrical connector 606 and the shaft circuit board610. The electrical connector 606 may extend proximally through aconnector opening 243 defined in the chassis mounting flange 242. SeeFIG. 7. U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, isincorporated by reference in its entirety. U.S. patent application Ser.No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSORSYSTEM, filed on Mar. 13, 2013, is incorporated by reference in itsentirety. Further details regarding slip ring assembly 600 may be foundin U.S. patent application Ser. No. 13/803,086.

As discussed above, the shaft assembly 200 can include a proximalportion which is fixably mounted to the handle 14 and a distal portionwhich is rotatable about a longitudinal axis. The rotatable distal shaftportion can be rotated relative to the proximal portion about the slipring assembly 600, as discussed above. The distal connector flange 601of the slip ring assembly 600 can be positioned within the rotatabledistal shaft portion. Moreover, further to the above, the switch drum500 can also be positioned within the rotatable distal shaft portion.When the rotatable distal shaft portion is rotated, the distal connectorflange 601 and the switch drum 500 can be rotated synchronously with oneanother. In addition, the switch drum 500 can be rotated between a firstposition and a second position relative to the distal connector flange601. When the switch drum 500 is in its first position, the articulationdrive system may be operably disengaged from the firing drive systemand, thus, the operation of the firing drive system may not articulatethe end effector 300 of the shaft assembly 200. When the switch drum 500is in its second position, the articulation drive system may be operablyengaged with the firing drive system and, thus, the operation of thefiring drive system may articulate the end effector 300 of the shaftassembly 200. When the switch drum 500 is moved between its firstposition and its second position, the switch drum 500 is moved relativeto distal connector flange 601. In various instances, the shaft assembly200 can comprise at least one sensor configured to detect the positionof the switch drum 500. Turning now to FIGS. 11 and 12, the distalconnector flange 601 can comprise a Hall effect sensor 605, for example,and the switch drum 500 can comprise a magnetic element, such aspermanent magnet 505, for example. The Hall effect sensor 605 can beconfigured to detect the position of the permanent magnet 505. When theswitch drum 500 is rotated between its first position and its secondposition, the permanent magnet 505 can move relative to the Hall effectsensor 605. In various instances, Hall effect sensor 605 can detectchanges in a magnetic field created when the permanent magnet 505 ismoved. The Hall effect sensor 605 can be in signal communication withthe shaft circuit board 610 and/or the handle circuit board 100, forexample. Based on the signal from the Hall effect sensor 605, amicrocontroller on the shaft circuit board 610 and/or the handle circuitboard 100 can determine whether the articulation drive system is engagedwith or disengaged from the firing drive system.

Referring again to FIGS. 3 and 7, the chassis 240 includes at least one,and preferably two, tapered attachment portions 244 formed thereon thatare adapted to be received within corresponding dovetail slots 702formed within a distal attachment flange portion 700 of the frame 20.Each dovetail slot 702 may be tapered or, stated another way, besomewhat V-shaped to seatingly receive the attachment portions 244therein. As can be further seen in FIGS. 3 and 7, a shaft attachment lug226 is formed on the proximal end of the intermediate firing shaft 222.As will be discussed in further detail below, when the interchangeableshaft assembly 200 is coupled to the handle 14, the shaft attachment lug226 is received in a firing shaft attachment cradle 126 formed in thedistal end 125 of the longitudinal drive member 120. See FIGS. 3 and 6.

Various shaft assembly embodiments employ a latch system 710 forremovably coupling the shaft assembly 200 to the housing 12 and morespecifically to the frame 20. As shown in FIG. 7, for example, in atleast one form, the latch system 710 includes a lock member or lock yoke712 that is movably coupled to the chassis 240. In the illustratedembodiment, for example, the lock yoke 712 has a U-shape with two spaceddownwardly extending legs 714. The legs 714 each have a pivot lug 716formed thereon that are adapted to be received in corresponding holes245 formed in the chassis 240. Such arrangement facilitates pivotalattachment of the lock yoke 712 to the chassis 240. The lock yoke 712may include two proximally protruding lock lugs 714 that are configuredfor releasable engagement with corresponding lock detents or grooves 704in the distal attachment flange 700 of the frame 20. See FIG. 3. Invarious forms, the lock yoke 712 is biased in the proximal direction byspring or biasing member (not shown). Actuation of the lock yoke 712 maybe accomplished by a latch button 722 that is slidably mounted on alatch actuator assembly 720 that is mounted to the chassis 240. Thelatch button 722 may be biased in a proximal direction relative to thelock yoke 712. As will be discussed in further detail below, the lockyoke 712 may be moved to an unlocked position by biasing the latchbutton the in distal direction which also causes the lock yoke 712 topivot out of retaining engagement with the distal attachment flange 700of the frame 20. When the lock yoke 712 is in “retaining engagement”with the distal attachment flange 700 of the frame 20, the lock lugs 716are retainingly seated within the corresponding lock detents or grooves704 in the distal attachment flange 700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 32 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 300 in a desiredorientation, the clinician may then fully actuate the closure trigger 32to close the anvil 306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 30 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 200 from the housing 12. One form of the latchsystem 710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 7, the lock yoke 712 includesat least one and preferably two lock hooks 718 that are adapted tocontact corresponding lock lug portions 256 that are formed on theclosure shuttle 250. Referring to FIGS. 13-15, when the closure shuttle250 is in an unactuated position (i.e., the first drive system 30 isunactuated and the anvil 306 is open), the lock yoke 712 may be pivotedin a distal direction to unlock the interchangeable shaft assembly 200from the housing 12. When in that position, the lock hooks 718 do notcontact the lock lug portions 256 on the closure shuttle 250. However,when the closure shuttle 250 is moved to an actuated position (i.e., thefirst drive system 30 is actuated and the anvil 306 is in the closedposition), the lock yoke 712 is prevented from being pivoted to anunlocked position. See FIGS. 16-18. Stated another way, if the clinicianwere to attempt to pivot the lock yoke 712 to an unlocked position or,for example, the lock yoke 712 was in advertently bumped or contacted ina manner that might otherwise cause it to pivot distally, the lock hooks718 on the lock yoke 712 will contact the lock lugs 256 on the closureshuttle 250 and prevent movement of the lock yoke 712 to an unlockedposition.

Attachment of the interchangeable shaft assembly 200 to the handle 14will now be described with reference to FIG. 3. To commence the couplingprocess, the clinician may position the chassis 240 of theinterchangeable shaft assembly 200 above or adjacent to the distalattachment flange 700 of the frame 20 such that the tapered attachmentportions 244 formed on the chassis 240 are aligned with the dovetailslots 702 in the frame 20. The clinician may then move the shaftassembly 200 along an installation axis IA that is perpendicular to theshaft axis SA-SA to seat the attachment portions 244 in “operableengagement” with the corresponding dovetail receiving slots 702. Indoing so, the shaft attachment lug 226 on the intermediate firing shaft222 will also be seated in the cradle 126 in the longitudinally movabledrive member 120 and the portions of pin 37 on the second closure link38 will be seated in the corresponding hooks 252 in the closure yoke250. As used herein, the term “operable engagement” in the context oftwo components means that the two components are sufficiently engagedwith each other so that upon application of an actuation motion thereto,the components may carry out their intended action, function and/orprocedure.

As discussed above, at least five systems of the interchangeable shaftassembly 200 can be operably coupled with at least five correspondingsystems of the handle 14. A first system can comprise a frame systemwhich couples and/or aligns the frame or spine of the shaft assembly 200with the frame 20 of the handle 14. Another system can comprise aclosure drive system 30 which can operably connect the closure trigger32 of the handle 14 and the closure tube 260 and the anvil 306 of theshaft assembly 200. As outlined above, the closure tube attachment yoke250 of the shaft assembly 200 can be engaged with the pin 37 on thesecond closure link 38. Another system can comprise the firing drivesystem 80 which can operably connect the firing trigger 130 of thehandle 14 with the intermediate firing shaft 222 of the shaft assembly200.

As outlined above, the shaft attachment lug 226 can be operablyconnected with the cradle 126 of the longitudinal drive member 120.Another system can comprise an electrical system which can signal to acontroller in the handle 14, such as microcontroller, for example, thata shaft assembly, such as shaft assembly 200, for example, has beenoperably engaged with the handle 14 and/or, two, conduct power and/orcommunication signals between the shaft assembly 200 and the handle 14.For instance, the shaft assembly 200 can include an electrical connector1410 that is operably mounted to the shaft circuit board 610. Theelectrical connector 1410 is configured for mating engagement with acorresponding electrical connector 1400 on the handle control board 100.Further details regaining the circuitry and control systems may be foundin U.S. patent application Ser. No. 13/803,086, the entire disclosure ofwhich was previously incorporated by reference herein. The fifth systemmay consist of the latching system for releasably locking the shaftassembly 200 to the handle 14.

Referring again to FIGS. 2 and 3, the handle 14 can include anelectrical connector 1400 comprising a plurality of electrical contacts.Turning now to FIG. 19, the electrical connector 1400 can comprise afirst contact 1401 a, a second contact 1401 b, a third contact 1401 c, afourth contact 1401 d, a fifth contact 1401 e, and a sixth contact 1401f, for example. While the illustrated embodiment utilizes six contacts,other embodiments are envisioned which may utilize more than sixcontacts or less than six contacts.

As illustrated in FIG. 19, the first contact 1401 a can be in electricalcommunication with a transistor 1408, contacts 1401 b-1401 e can be inelectrical communication with a microcontroller 1500, and the sixthcontact 1401 f can be in electrical communication with a ground. Incertain circumstances, one or more of the electrical contacts 1401b-1401 e may be in electrical communication with one or more outputchannels of the microcontroller 1500 and can be energized, or have avoltage potential applied thereto, when the handle 1042 is in a poweredstate. In some circumstances, one or more of the electrical contacts1401 b-1401 e may be in electrical communication with one or more inputchannels of the microcontroller 1500 and, when the handle 14 is in apowered state, the microcontroller 1500 can be configured to detect whena voltage potential is applied to such electrical contacts. When a shaftassembly, such as shaft assembly 200, for example, is assembled to thehandle 14, the electrical contacts 1401 a-1401 f may not communicatewith each other. When a shaft assembly is not assembled to the handle14, however, the electrical contacts 1401 a-1401 f of the electricalconnector 1400 may be exposed and, in some circumstances, one or more ofthe contacts 1401 a-1401 f may be accidentally placed in electricalcommunication with each other. Such circumstances can arise when one ormore of the contacts 1401 a-1401 f come into contact with anelectrically conductive material, for example. When this occurs, themicrocontroller 1500 can receive an erroneous input and/or the shaftassembly 200 can receive an erroneous output, for example. To addressthis issue, in various circumstances, the handle 14 may be unpoweredwhen a shaft assembly, such as shaft assembly 200, for example, is notattached to the handle 14.

In other circumstances, the handle 1042 can be powered when a shaftassembly, such as shaft assembly 200, for example, is not attachedthereto. In such circumstances, the microcontroller 1500 can beconfigured to ignore inputs, or voltage potentials, applied to thecontacts in electrical communication with the microcontroller 1500,i.e., contacts 1401 b-1401 e, for example, until a shaft assembly isattached to the handle 14. Even though the microcontroller 1500 may besupplied with power to operate other functionalities of the handle 14 insuch circumstances, the handle 14 may be in a powered-down state. In away, the electrical connector 1400 may be in a powered-down state asvoltage potentials applied to the electrical contacts 1401 b-1401 e maynot affect the operation of the handle 14. The reader will appreciatethat, even though contacts 1401 b-1401 e may be in a powered-down state,the electrical contacts 1401 a and 1401 f, which are not in electricalcommunication with the microcontroller 1500, may or may not be in apowered-down state. For instance, sixth contact 1401 f may remain inelectrical communication with a ground regardless of whether the handle14 is in a powered-up or a powered-down state.

Furthermore, the transistor 1408, and/or any other suitable arrangementof transistors, such as transistor 1410, for example, and/or switchesmay be configured to control the supply of power from a power source1404, such as a battery 90 within the handle 14, for example, to thefirst electrical contact 1401 a regardless of whether the handle 14 isin a powered-up or a powered-down state. In various circumstances, theshaft assembly 200, for example, can be configured to change the stateof the transistor 1408 when the shaft assembly 200 is engaged with thehandle 14. In certain circumstances, further to the below, a Hall effectsensor 1402 can be configured to switch the state of transistor 1410which, as a result, can switch the state of transistor 1408 andultimately supply power from power source 1404 to first contact 1401 a.In this way, both the power circuits and the signal circuits to theconnector 1400 can be powered down when a shaft assembly is notinstalled to the handle 14 and powered up when a shaft assembly isinstalled to the handle 14.

In various circumstances, referring again to FIG. 19, the handle 14 caninclude the Hall effect sensor 1402, for example, which can beconfigured to detect a detectable element, such as a magnetic element1407 (FIG. 3), for example, on a shaft assembly, such as shaft assembly200, for example, when the shaft assembly is coupled to the handle 14.The Hall effect sensor 1402 can be powered by a power source 1406, suchas a battery, for example, which can, in effect, amplify the detectionsignal of the Hall effect sensor 1402 and communicate with an inputchannel of the microcontroller 1500 via the circuit illustrated in FIG.19. Once the microcontroller 1500 has a received an input indicatingthat a shaft assembly has been at least partially coupled to the handle14, and that, as a result, the electrical contacts 1401 a-1401 f are nolonger exposed, the microcontroller 1500 can enter into its normal, orpowered-up, operating state. In such an operating state, themicrocontroller 1500 will evaluate the signals transmitted to one ormore of the contacts 1401 b-1401 e from the shaft assembly and/ortransmit signals to the shaft assembly through one or more of thecontacts 1401 b-1401 e in normal use thereof. In various circumstances,the shaft assembly 200 may have to be fully seated before the Halleffect sensor 1402 can detect the magnetic element 1407. While a Halleffect sensor 1402 can be utilized to detect the presence of the shaftassembly 200, any suitable system of sensors and/or switches can beutilized to detect whether a shaft assembly has been assembled to thehandle 14, for example. In this way, further to the above, both thepower circuits and the signal circuits to the connector 1400 can bepowered down when a shaft assembly is not installed to the handle 14 andpowered up when a shaft assembly is installed to the handle 14.

In various embodiments, any number of magnetic sensing elements may beemployed to detect whether a shaft assembly has been assembled to thehandle 14, for example. For example, the technologies used for magneticfield sensing include search coil, fluxgate, optically pumped, nuclearprecession, SQUID, Hall-effect, anisotropic magnetoresistance, giantmagnetoresistance, magnetic tunnel junctions, giant magnetoimpedance,magnetostrictive/piezoelectric composites, magnetodiode,magnetotransistor, fiber optic, magnetooptic, and microelectromechanicalsystems-based magnetic sensors, among others.

Referring to FIG. 19, the microcontroller 1500 may generally comprise amicroprocessor (“processor”) and one or more memory units operationallycoupled to the processor. By executing instruction code stored in thememory, the processor may control various components of the surgicalinstrument, such as the motor, various drive systems, and/or a userdisplay, for example. The microcontroller 1500 may be implemented usingintegrated and/or discrete hardware elements, software elements, and/ora combination of both. Examples of integrated hardware elements mayinclude processors, microprocessors, microcontrollers, integratedcircuits, application specific integrated circuits (ASIC), programmablelogic devices (PLD), digital signal processors (DSP), field programmablegate arrays (FPGA), logic gates, registers, semiconductor devices,chips, microchips, chip sets, microcontrollers, system-on-chip (SoC),and/or system-in-package (SIP). Examples of discrete hardware elementsmay include circuits and/or circuit elements such as logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, and/or relays. In certain instances, the microcontroller 1500may include a hybrid circuit comprising discrete and integrated circuitelements or components on one or more substrates, for example.

Referring to FIG. 19, the microcontroller 1500 may be an LM 4F230H5QR,available from Texas Instruments, for example. In certain instances, theTexas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available. Other microcontrollersmay be readily substituted for use with the present disclosure.Accordingly, the present disclosure should not be limited in thiscontext.

As discussed above, the handle 14 and/or the shaft assembly 200 caninclude systems and configurations configured to prevent, or at leastreduce the possibility of, the contacts of the handle electricalconnector 1400 and/or the contacts of the shaft electrical connector1410 from becoming shorted out when the shaft assembly 200 is notassembled, or completely assembled, to the handle 14. Referring to FIG.3, the handle electrical connector 1400 can be at least partiallyrecessed within a cavity 1409 defined in the handle frame 20. The sixcontacts 1401 a-1401 f of the electrical connector 1400 can becompletely recessed within the cavity 1409. Such arrangements can reducethe possibility of an object accidentally contacting one or more of thecontacts 1401 a-1401 f. Similarly, the shaft electrical connector 1410can be positioned within a recess defined in the shaft chassis 240 whichcan reduce the possibility of an object accidentally contacting one ormore of the contacts 1411 a-1411 f of the shaft electrical connector1410. With regard to the particular embodiment depicted in FIG. 3, theshaft contacts 1411 a-1411 f can comprise male contacts. In at least oneembodiment, each shaft contact 1411 a-1411 f can comprise a flexibleprojection extending therefrom which can be configured to engage acorresponding handle contact 1401 a-1401 f, for example. The handlecontacts 1401 a-1401 f can comprise female contacts. In at least oneembodiment, each handle contact 1401 a-1401 f can comprise a flatsurface, for example, against which the male shaft contacts 1401 a-1401f can wipe, or slide, against and maintain an electrically conductiveinterface therebetween. In various instances, the direction in which theshaft assembly 200 is assembled to the handle 14 can be parallel to, orat least substantially parallel to, the handle contacts 1401 a-1401 fsuch that the shaft contacts 1411 a-1411 f slide against the handlecontacts 1401 a-1401 f when the shaft assembly 200 is assembled to thehandle 14. In various alternative embodiments, the handle contacts 1401a-1401 f can comprise male contacts and the shaft contacts 1411 a-1411 fcan comprise female contacts. In certain alternative embodiments, thehandle contacts 1401 a-1401 f and the shaft contacts 1411 a-1411 f cancomprise any suitable arrangement of contacts.

In various instances, the handle 14 can comprise a connector guardconfigured to at least partially cover the handle electrical connector1400 and/or a connector guard configured to at least partially cover theshaft electrical connector 1410. A connector guard can prevent, or atleast reduce the possibility of, an object accidentally touching thecontacts of an electrical connector when the shaft assembly is notassembled to, or only partially assembled to, the handle. A connectorguard can be movable. For instance, the connector guard can be movedbetween a guarded position in which it at least partially guards aconnector and an unguarded position in which it does not guard, or atleast guards less of, the connector. In at least one embodiment, aconnector guard can be displaced as the shaft assembly is beingassembled to the handle. For instance, if the handle comprises a handleconnector guard, the shaft assembly can contact and displace the handleconnector guard as the shaft assembly is being assembled to the handle.Similarly, if the shaft assembly comprises a shaft connector guard, thehandle can contact and displace the shaft connector guard as the shaftassembly is being assembled to the handle. In various instances, aconnector guard can comprise a door, for example. In at least oneinstance, the door can comprise a beveled surface which, when contactedby the handle or shaft, can facilitate the displacement of the door in acertain direction. In various instances, the connector guard can betranslated and/or rotated, for example. In certain instances, aconnector guard can comprise at least one film which covers the contactsof an electrical connector. When the shaft assembly is assembled to thehandle, the film can become ruptured. In at least one instance, the malecontacts of a connector can penetrate the film before engaging thecorresponding contacts positioned underneath the film.

As described above, the surgical instrument can include a system whichcan selectively power-up, or activate, the contacts of an electricalconnector, such as the electrical connector 1400, for example. Invarious instances, the contacts can be transitioned between anunactivated condition and an activated condition. In certain instances,the contacts can be transitioned between a monitored condition, adeactivated condition, and an activated condition. For instance, themicrocontroller 1500, for example, can monitor the contacts 1401 a-1401f when a shaft assembly has not been assembled to the handle 14 todetermine whether one or more of the contacts 1401 a-1401 f may havebeen shorted. The microcontroller 1500 can be configured to apply a lowvoltage potential to each of the contacts 1401 a-1401 f and assesswhether only a minimal resistance is present at each of the contacts.Such an operating state can comprise the monitored condition. In theevent that the resistance detected at a contact is high, or above athreshold resistance, the microcontroller 1500 can deactivate thatcontact, more than one contact, or, alternatively, all of the contacts.Such an operating state can comprise the deactivated condition. If ashaft assembly is assembled to the handle 14 and it is detected by themicrocontroller 1500, as discussed above, the microcontroller 1500 canincrease the voltage potential to the contacts 1401 a-1401 f. Such anoperating state can comprise the activated condition.

The various shaft assemblies disclosed herein may employ sensors andvarious other components that require electrical communication with thecontroller in the housing. These shaft assemblies generally areconfigured to be able to rotate relative to the housing necessitating aconnection that facilitates such electrical communication between two ormore components that may rotate relative to each other. When employingend effectors of the types disclosed herein, the connector arrangementsmust be relatively robust in nature while also being somewhat compact tofit into the shaft assembly connector portion.

Referring to FIG. 20, a non-limiting form of the end effector 300 isillustrated. As described above, the end effector 300 may include theanvil 306 and the staple cartridge 304. In this non-limiting embodiment,the anvil 306 is coupled to an elongate channel 198. For example,apertures 199 can be defined in the elongate channel 198 which canreceive pins 152 extending from the anvil 306 and allow the anvil 306 topivot from an open position to a closed position relative to theelongate channel 198 and staple cartridge 304. In addition, FIG. 20shows a firing bar 172, configured to longitudinally translate into theend effector 300. The firing bar 172 may be constructed from one solidsection, or in various embodiments, may include a laminate materialcomprising, for example, a stack of steel plates. A distally projectingend of the firing bar 172 can be attached to an E-beam 178 that can,among other things, assist in spacing the anvil 306 from a staplecartridge 304 positioned in the elongate channel 198 when the anvil 306is in a closed position. The E-beam 178 can also include a sharpenedcutting edge 182 which can be used to sever tissue as the E-beam 178 isadvanced distally by the firing bar 172. In operation, the E-beam 178can also actuate, or fire, the staple cartridge 304. The staplecartridge 304 can include a molded cartridge body 194 that holds aplurality of staples 191 resting upon staple drivers 192 withinrespective upwardly open staple cavities 195. A wedge sled 190 is drivendistally by the E-beam 178, sliding upon a cartridge tray 196 that holdstogether the various components of the replaceable staple cartridge 304.The wedge sled 190 upwardly cams the staple drivers 192 to force out thestaples 191 into deforming contact with the anvil 306 while a cuttingsurface 182 of the E-beam 178 severs clamped tissue.

Further to the above, the E-beam 178 can include upper pins 180 whichengage the anvil 306 during firing. The E-beam 178 can further includemiddle pins 184 and a bottom foot 186 which can engage various portionsof the cartridge body 194, cartridge tray 196 and elongate channel 198.When a staple cartridge 304 is positioned within the elongate channel198, a slot 193 defined in the cartridge body 194 can be aligned with aslot 197 defined in the cartridge tray 196 and a slot 189 defined in theelongate channel 198. In use, the E-beam 178 can slide through thealigned slots 193, 197, and 189 wherein, as indicated in FIG. 20, thebottom foot 186 of the E-beam 178 can engage a groove running along thebottom surface of channel 198 along the length of slot 189, the middlepins 184 can engage the top surfaces of cartridge tray 196 along thelength of longitudinal slot 197, and the upper pins 180 can engage theanvil 306. In such circumstances, the E-beam 178 can space, or limit therelative movement between, the anvil 306 and the staple cartridge 304 asthe firing bar 172 is moved distally to fire the staples from the staplecartridge 304 and/or incise the tissue captured between the anvil 306and the staple cartridge 304. Thereafter, the firing bar 172 and theE-beam 178 can be retracted proximally allowing the anvil 306 to beopened to release the two stapled and severed tissue portions (notshown).

Having described a surgical instrument 10 in general terms, thedescription now turns to a detailed description of variouselectrical/electronic component of the surgical instrument 10. Turningnow to FIGS. 21A-21B, where one embodiment of a segmented circuit 2000comprising a plurality of circuit segments 2002 a-2002 g is illustrated.The segmented circuit 2000 comprising the plurality of circuit segments2002 a-2002 g is configured to control a powered surgical instrument,such as, for example, the surgical instrument 10 illustrated in FIGS.1-18A, without limitation. The plurality of circuit segments 2002 a-2002g is configured to control one or more operations of the poweredsurgical instrument 10. A safety processor segment 2002 a (Segment 1)comprises a safety processor 2004. A primary processor segment 2002 b(Segment 2) comprises a primary processor 2006. The safety processor2004 and/or the primary processor 2006 are configured to interact withone or more additional circuit segments 2002 c-2002 g to controloperation of the powered surgical instrument 10. The primary processor2006 comprises a plurality of inputs coupled to, for example, one ormore circuit segments 2002 c-2002 g, a battery 2008, and/or a pluralityof switches 2058 a-2070. The segmented circuit 2000 may be implementedby any suitable circuit, such as, for example, a printed circuit boardassembly (PCBA) within the powered surgical instrument 10. It should beunderstood that the term processor as used herein includes anymicroprocessor, microcontroller, or other basic computing device thatincorporates the functions of a computer's central processing unit (CPU)on an integrated circuit or at most a few integrated circuits. Theprocessor is a multipurpose, programmable device that accepts digitaldata as input, processes it according to instructions stored in itsmemory, and provides results as output. It is an example of sequentialdigital logic, as it has internal memory. Processors operate on numbersand symbols represented in the binary numeral system.

In one embodiment, the main processor 2006 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one embodiment, the safety processor 2004 maybe a safety microcontroller platform comprising twomicrocontroller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments.Nevertheless, other suitable substitutes for microcontrollers and safetyprocessor may be employed, without limitation. In one embodiment, thesafety processor 2004 may be configured specifically for IEC 61508 andISO 26262 safety critical applications, among others, to provideadvanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

In certain instances, the main processor 2006 may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle SRAM, internal ROM loadedwith StellarisWare® software, 2 KB EEPROM, one or more PWM modules, oneor more QEI analog, one or more 12-bit ADC with 12 analog inputchannels, among other features that are readily available for theproduct datasheet. Other processors may be readily substituted and,accordingly, the present disclosure should not be limited in thiscontext.

In one embodiment, the segmented circuit 2000 comprises an accelerationsegment 2002 c (Segment 3). The acceleration segment 2002 c comprises anacceleration sensor 2022. The acceleration sensor 2022 may comprise, forexample, an accelerometer. The acceleration sensor 2022 is configured todetect movement or acceleration of the powered surgical instrument 10.In some embodiments, input from the acceleration sensor 2022 is used,for example, to transition to and from a sleep mode, identify anorientation of the powered surgical instrument, and/or identify when thesurgical instrument has been dropped. In some embodiments, theacceleration segment 2002 c is coupled to the safety processor 2004and/or the primary processor 2006.

In one embodiment, the segmented circuit 2000 comprises a displaysegment 2002 d (Segment 4). The display segment 2002 d comprises adisplay connector 2024 coupled to the primary processor 2006. Thedisplay connector 2024 couples the primary processor 2006 to a display2028 through one or more display driver integrated circuits 2026. Thedisplay driver integrated circuits 2026 may be integrated with thedisplay 2028 and/or may be located separately from the display 2028. Thedisplay 2028 may comprise any suitable display, such as, for example, anorganic light-emitting diode (OLED) display, a liquid-crystal display(LCD), and/or any other suitable display. In some embodiments, thedisplay segment 2002 d is coupled to the safety processor 2004.

In some embodiments, the segmented circuit 2000 comprises a shaftsegment 2002 e (Segment 5). The shaft segment 2002 e comprises one ormore controls for a shaft 2004 coupled to the surgical instrument 10and/or one or more controls for an end effector 2006 coupled to theshaft 2004. The shaft segment 2002 e comprises a shaft connector 2030configured to couple the primary processor 2006 to a shaft PCBA 2031.The shaft PCBA 2031 comprises a first articulation switch 2036, a secondarticulation switch 2032, and a shaft PCBA EEPROM 2034. In someembodiments, the shaft PCBA EEPROM 2034 comprises one or moreparameters, routines, and/or programs specific to the shaft 2004 and/orthe shaft PCBA 2031. The shaft PCBA 2031 may be coupled to the shaft2004 and/or integral with the surgical instrument 10. In someembodiments, the shaft segment 2002 e comprises a second shaft EEPROM2038. The second shaft EEPROM 2038 comprises a plurality of algorithms,routines, parameters, and/or other data corresponding to one or moreshafts 2004 and/or end effectors 2006 which may be interfaced with thepowered surgical instrument 10.

In some embodiments, the segmented circuit 2000 comprises a positionencoder segment 2002 f (Segment 6). The position encoder segment 2002 fcomprises one or more magnetic rotary position encoders 2040 a-2040 b.The one or more magnetic rotary position encoders 2040 a-2040 b areconfigured to identify the rotational position of a motor 2048, a shaft2004, and/or an end effector 2006 of the surgical instrument 10. In someembodiments, the magnetic rotary position encoders 2040 a-2040 b may becoupled to the safety processor 2004 and/or the primary processor 2006.

In some embodiments, the segmented circuit 2000 comprises a motorsegment 2002 g (Segment 7). The motor segment 2002 g comprises a motor2048 configured to control one or more movements of the powered surgicalinstrument 10. The motor 2048 is coupled to the primary processor 2006by an H-Bridge driver 2042 and one or more H-bridge field-effecttransistors (FETs) 2044. The H-bridge FETs 2044 are coupled to thesafety processor 2004. A motor current sensor 2046 is coupled in serieswith the motor 2048 to measure the current draw of the motor 2048. Themotor current sensor 2046 is in signal communication with the primaryprocessor 2006 and/or the safety processor 2004. In some embodiments,the motor 2048 is coupled to a motor electromagnetic interference (EMI)filter 2050.

The segmented circuit 2000 comprises a power segment 2002 h (Segment 8).A battery 2008 is coupled to the safety processor 2004, the primaryprocessor 2006, and one or more of the additional circuit segments 2002c-2002 g. The battery 2008 is coupled to the segmented circuit 2000 by abattery connector 2010 and a current sensor 2012. The current sensor2012 is configured to measure the total current draw of the segmentedcircuit 2000. In some embodiments, one or more voltage converters 2014a, 2014 b, 2016 are configured to provide predetermined voltage valuesto one or more circuit segments 2002 a-2002 g. For example, in someembodiments, the segmented circuit 2000 may comprise 3.3V voltageconverters 2014 a-2014 b and/or 5V voltage converters 2016. A boostconverter 2018 is configured to provide a boost voltage up to apredetermined amount, such as, for example, up to 13V. The boostconverter 2018 is configured to provide additional voltage and/orcurrent during power intensive operations and prevent brownout orlow-power conditions.

In some embodiments, the safety segment 2002 a comprises a motor powerinterrupt 2020. The motor power interrupt 2020 is coupled between thepower segment 2002 h and the motor segment 2002 g. The safety segment2002 a is configured to interrupt power to the motor segment 2002 g whenan error or fault condition is detected by the safety processor 2004and/or the primary processor 2006 as discussed in more detail herein.Although the circuit segments 2002 a-2002 g are illustrated with allcomponents of the circuit segments 2002 a-2002 h located in physicalproximity, one skilled in the art will recognize that a circuit segment2002 a-2002 h may comprise components physically and/or electricallyseparate from other components of the same circuit segment 2002 a-2002g. In some embodiments, one or more components may be shared between twoor more circuit segments 2002 a-2002 g.

In some embodiments, a plurality of switches 2056-2070 are coupled tothe safety processor 2004 and/or the primary processor 2006. Theplurality of switches 2056-2070 may be configured to control one or moreoperations of the surgical instrument 10, control one or more operationsof the segmented circuit 2000, and/or indicate a status of the surgicalinstrument 10. For example, a bail-out door switch 2056 is configured toindicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch2058 a, a left side articulation right switch 2060 a, a left sidearticulation center switch 2062 a, a right side articulation left switch2058 b, a right side articulation right switch 2060 b, and a right sidearticulation center switch 2062 b are configured to control articulationof a shaft 2004 and/or an end effector 2006. A left side reverse switch2064 a and a right side reverse switch 2064 b are coupled to the primaryprocessor 2006. In some embodiments, the left side switches comprisingthe left side articulation left switch 2058 a, the left sidearticulation right switch 2060 a, the left side articulation centerswitch 2062 a, and the left side reverse switch 2064 a are coupled tothe primary processor 2006 by a left flex connector 2072 a. The rightside switches comprising the right side articulation left switch 2058 b,the right side articulation right switch 2060 b, the right sidearticulation center switch 2062 b, and the right side reverse switch2064 b are coupled to the primary processor 2006 by a right flexconnector 2072 b. In some embodiments, a firing switch 2066, a clamprelease switch 2068, and a shaft engaged switch 2070 are coupled to theprimary processor 2006.

The plurality of switches 2056-2070 may comprise, for example, aplurality of handle controls mounted to a handle of the surgicalinstrument 10, a plurality of indicator switches, and/or any combinationthereof. In various embodiments, the plurality of switches 2056-2070allow a surgeon to manipulate the surgical instrument, provide feedbackto the segmented circuit 2000 regarding the position and/or operation ofthe surgical instrument, and/or indicate unsafe operation of thesurgical instrument 10. In some embodiments, additional or fewerswitches may be coupled to the segmented circuit 2000, one or more ofthe switches 2056-2070 may be combined into a single switch, and/orexpanded to multiple switches. For example, in one embodiment, one ormore of the left side and/or right side articulation switches 2058a-2064 b may be combined into a single multi-position switch.

In one embodiment, the safety processor 2004 is configured to implementa watchdog function, among other safety operations. The safety processor2004 and the primary processor 2006 of the segmented circuit 2000 are insignal communication. A microprocessor alive heartbeat signal isprovided at output 2096. The acceleration segment 2002 c comprises anaccelerometer 2022 configured to monitor movement of the surgicalinstrument 10. In various embodiments, the accelerometer 2022 may be asingle, double, or triple axis accelerometer. The accelerometer 2022 maybe employed to measures proper acceleration that is not necessarily thecoordinate acceleration (rate of change of velocity). Instead, theaccelerometer sees the acceleration associated with the phenomenon ofweight experienced by a test mass at rest in the frame of reference ofthe accelerometer 2022. For example, the accelerometer 2022 at rest onthe surface of the earth will measure an acceleration g=9.8 m/s²(gravity) straight upwards, due to its weight. Another type ofacceleration that accelerometer 2022 can measure is g-forceacceleration. In various other embodiments, the accelerometer 2022 maycomprise a single, double, or triple axis accelerometer. Further, theacceleration segment 2002 c may comprise one or more inertial sensors todetect and measure acceleration, tilt, shock, vibration, rotation, andmultiple degrees-of-freedom (DoF). A suitable inertial sensor maycomprise an accelerometer (single, double, or triple axis), amagnetometer to measure a magnetic field in space such as the earth'smagnetic field, and/or a gyroscope to measure angular velocity.

In one embodiment, the safety processor 2004 is configured to implementa watchdog function with respect to one or more circuit segments 2002c-2002 h, such as, for example, the motor segment 2002 g. In thisregards, the safety processor 2004 employs the watchdog function todetect and recover from malfunctions of the primary processor 2006.During normal operation, the safety processor 2004 monitors for hardwarefaults or program errors of the primary processor 2004 and to initiatecorrective action or actions. The corrective actions may include placingthe primary processor 2006 in a safe state and restoring normal systemoperation. In one embodiment, the safety processor 2004 is coupled to atleast a first sensor. The first sensor measures a first property of thesurgical instrument 10. In some embodiments, the safety processor 2004is configured to compare the measured property of the surgicalinstrument 10 to a predetermined value. For example, in one embodiment,a motor sensor 2040 a is coupled to the safety processor 2004. The motorsensor 2040 a provides motor speed and position information to thesafety processor 2004. The safety processor 2004 monitors the motorsensor 2040 a and compares the value to a maximum speed and/or positionvalue and prevents operation of the motor 2048 above the predeterminedvalues. In some embodiments, the predetermined values are calculatedbased on real-time speed and/or position of the motor 2048, calculatedfrom values supplied by a second motor sensor 2040 b in communicationwith the primary processor 2006, and/or provided to the safety processor2004 from, for example, a memory module coupled to the safety processor2004.

In some embodiments, a second sensor is coupled to the primary processor2006. The second sensor is configured to measure the first physicalproperty. The safety processor 2004 and the primary processor 2006 areconfigured to provide a signal indicative of the value of the firstsensor and the second sensor respectively. When either the safetyprocessor 2004 or the primary processor 2006 indicates a value outsideof an acceptable range, the segmented circuit 2000 prevents operation ofat least one of the circuit segments 2002 c-2002 h, such as, forexample, the motor segment 2002 g. For example, in the embodimentillustrated in FIGS. 21A-21B, the safety processor 2004 is coupled to afirst motor position sensor 2040 a and the primary processor 2006 iscoupled to a second motor position sensor 2040 b. The motor positionsensors 2040 a, 2040 b may comprise any suitable motor position sensor,such as, for example, a magnetic angle rotary input comprising a sineand cosine output. The motor position sensors 2040 a, 2040 b providerespective signals to the safety processor 2004 and the primaryprocessor 2006 indicative of the position of the motor 2048.

The safety processor 2004 and the primary processor 2006 generate anactivation signal when the values of the first motor sensor 2040 a andthe second motor sensor 2040 b are within a predetermined range. Wheneither the primary processor 2006 or the safety processor 2004 to detecta value outside of the predetermined range, the activation signal isterminated and operation of at least one circuit segment 2002 c-2002 h,such as, for example, the motor segment 2002 g, is interrupted and/orprevented. For example, in some embodiments, the activation signal fromthe primary processor 2006 and the activation signal from the safetyprocessor 2004 are coupled to an AND gate. The AND gate is coupled to amotor power switch 2020. The AND gate maintains the motor power switch2020 in a closed, or on, position when the activation signal from boththe safety processor 2004 and the primary processor 2006 are high,indicating a value of the motor sensors 2040 a, 2040 b within thepredetermined range. When either of the motor sensors 2040 a, 2040 bdetect a value outside of the predetermined range, the activation signalfrom that motor sensor 2040 a, 2040 b is set low, and the output of theAND gate is set low, opening the motor power switch 2020. In someembodiments, the value of the first sensor 2040 a and the second sensor2040 b is compared, for example, by the safety processor 2004 and/or theprimary processor 2006. When the values of the first sensor and thesecond sensor are different, the safety processor 2004 and/or theprimary processor 2006 may prevent operation of the motor segment 2002g.

In some embodiments, the safety processor 2004 receives a signalindicative of the value of the second sensor 2040 b and compares thesecond sensor value to the first sensor value. For example, in oneembodiment, the safety processor 2004 is coupled directly to a firstmotor sensor 2040 a. A second motor sensor 2040 b is coupled to aprimary processor 2006, which provides the second motor sensor 2040 bvalue to the safety processor 2004, and/or coupled directly to thesafety processor 2004. The safety processor 2004 compares the value ofthe first motor sensor 2040 to the value of the second motor sensor 2040b. When the safety processor 2004 detects a mismatch between the firstmotor sensor 2040 a and the second motor sensor 2040 b, the safetyprocessor 2004 may interrupt operation of the motor segment 2002 g, forexample, by cutting power to the motor segment 2002 g.

In some embodiments, the safety processor 2004 and/or the primaryprocessor 2006 is coupled to a first sensor 2040 a configured to measurea first property of a surgical instrument and a second sensor 2040 bconfigured to measure a second property of the surgical instrument. Thefirst property and the second property comprise a predeterminedrelationship when the surgical instrument is operating normally. Thesafety processor 2004 monitors the first property and the secondproperty. When a value of the first property and/or the second propertyinconsistent with the predetermined relationship is detected, a faultoccurs. When a fault occurs, the safety processor 2004 takes at leastone action, such as, for example, preventing operation of at least oneof the circuit segments, executing a predetermined operation, and/orresetting the primary processor 2006. For example, the safety processor2004 may open the motor power switch 2020 to cut power to the motorcircuit segment 2002 g when a fault is detected.

In one embodiment, the safety processor 2004 is configured to execute anindependent control algorithm. In operation, the safety processor 2004monitors the segmented circuit 2000 and is configured to control and/oroverride signals from other circuit components, such as, for example,the primary processor 2006, independently. The safety processor 2004 mayexecute a preprogrammed algorithm and/or may be updated or programmed onthe fly during operation based on one or more actions and/or positionsof the surgical instrument 10. For example, in one embodiment, thesafety processor 2004 is reprogrammed with new parameters and/or safetyalgorithms each time a new shaft and/or end effector is coupled to thesurgical instrument 10. In some embodiments, one or more safety valuesstored by the safety processor 2004 are duplicated by the primaryprocessor 2006. Two-way error detection is performed to ensure valuesand/or parameters stored by either of the processors 2004, 2006 arecorrect.

In some embodiments, the safety processor 2004 and the primary processor2006 implement a redundant safety check. The safety processor 2004 andthe primary processor 2006 provide periodic signals indicating normaloperation. For example, during operation, the safety processor 2004 mayindicate to the primary processor 2006 that the safety processor 2004 isexecuting code and operating normally. The primary processor 2006 may,likewise, indicate to the safety processor 2004 that the primaryprocessor 2006 is executing code and operating normally. In someembodiments, communication between the safety processor 2004 and theprimary processor 2006 occurs at a predetermined interval. Thepredetermined interval may be constant or may be variable based on thecircuit state and/or operation of the surgical instrument 10.

FIG. 22 illustrates one example of a power assembly 2100 comprising ausage cycle circuit 2102 configured to monitor a usage cycle count ofthe power assembly 2100. The power assembly 2100 may be coupled to asurgical instrument 2110. The usage cycle circuit 2102 comprises aprocessor 2104 and a use indicator 2106. The use indicator 2106 isconfigured to provide a signal to the processor 2104 to indicate a useof the battery back 2100 and/or a surgical instrument 2110 coupled tothe power assembly 2100. A “use” may comprise any suitable action,condition, and/or parameter such as, for example, changing a modularcomponent of a surgical instrument 2110, deploying or firing adisposable component coupled to the surgical instrument 2110, deliveringelectrosurgical energy from the surgical instrument 2110, reconditioningthe surgical instrument 2110 and/or the power assembly 2100, exchangingthe power assembly 2100, recharging the power assembly 2100, and/orexceeding a safety limitation of the surgical instrument 2110 and/or thebattery back 2100.

In some instances, a usage cycle, or use, is defined by one or morepower assembly 2100 parameters. For example, in one instance, a usagecycle comprises using more than 5% of the total energy available fromthe power assembly 2100 when the power assembly 2100 is at a full chargelevel. In another instance, a usage cycle comprises a continuous energydrain from the power assembly 2100 exceeding a predetermined time limit.For example, a usage cycle may correspond to five minutes of continuousand/or total energy draw from the power assembly 2100. In someinstances, the power assembly 2100 comprises a usage cycle circuit 2102having a continuous power draw to maintain one or more components of theusage cycle circuit 2102, such as, for example, the use indicator 2106and/or a counter 2108, in an active state.

The processor 2104 maintains a usage cycle count. The usage cycle countindicates the number of uses detected by the use indicator 2106 for thepower assembly 2100 and/or the surgical instrument 2110. The processor2104 may increment and/or decrement the usage cycle count based on inputfrom the use indicator 2106. The usage cycle count is used to controlone or more operations of the power assembly 2100 and/or the surgicalinstrument 2110. For example, in some instances, a power assembly 2100is disabled when the usage cycle count exceeds a predetermined usagelimit. Although the instances discussed herein are discussed withrespect to incrementing the usage cycle count above a predeterminedusage limit, those skilled in the art will recognize that the usagecycle count may start at a predetermined amount and may be decrementedby the processor 2104. In this instance, the processor 2104 initiatesand/or prevents one or more operations of the power assembly 2100 whenthe usage cycle count falls below a predetermined usage limit.

The usage cycle count is maintained by a counter 2108. The counter 2108comprises any suitable circuit, such as, for example, a memory module,an analog counter, and/or any circuit configured to maintain a usagecycle count. In some instances, the counter 2108 is formed integrallywith the processor 2104. In other instances, the counter 2108 comprisesa separate component, such as, for example, a solid state memory module.In some instances, the usage cycle count is provided to a remote system,such as, for example, a central database. The usage cycle count istransmitted by a communications module 2112 to the remote system. Thecommunications module 2112 is configured to use any suitablecommunications medium, such as, for example, wired and/or wirelesscommunication. In some instances, the communications module 2112 isconfigured to receive one or more instructions from the remote system,such as, for example, a control signal when the usage cycle countexceeds the predetermined usage limit.

In some instances, the use indicator 2106 is configured to monitor thenumber of modular components used with a surgical instrument 2110coupled to the power assembly 2100. A modular component may comprise,for example, a modular shaft, a modular end effector, and/or any othermodular component. In some instances, the use indicator 2106 monitorsthe use of one or more disposable components, such as, for example,insertion and/or deployment of a staple cartridge within an end effectorcoupled to the surgical instrument 2110. The use indicator 2106comprises one or more sensors for detecting the exchange of one or moremodular and/or disposable components of the surgical instrument 2110.

In some instances, the use indicator 2106 is configured to monitorsingle patient surgical procedures performed while the power assembly2100 is installed. For example, the use indicator 2106 may be configuredto monitor firings of the surgical instrument 2110 while the powerassembly 2100 is coupled to the surgical instrument 2110. A firing maycorrespond to deployment of a staple cartridge, application ofelectrosurgical energy, and/or any other suitable surgical event. Theuse indicator 2106 may comprise one or more circuits for measuring thenumber of firings while the power assembly 2100 is installed. The useindicator 2106 provides a signal to the processor 2104 when a singlepatient procedure is performed and the processor 2104 increments theusage cycle count.

In some instances, the use indicator 2106 comprises a circuit configuredto monitor one or more parameters of the power source 2114, such as, forexample, a current draw from the power source 2114. The one or moreparameters of the power source 2114 correspond to one or more operationsperformable by the surgical instrument 2110, such as, for example, acutting and sealing operation. The use indicator 2106 provides the oneor more parameters to the processor 2104, which increments the usagecycle count when the one or more parameters indicate that a procedurehas been performed.

In some instances, the use indicator 2106 comprises a timing circuitconfigured to increment a usage cycle count after a predetermined timeperiod. The predetermined time period corresponds to a single patientprocedure time, which is the time required for an operator to perform aprocedure, such as, for example, a cutting and sealing procedure. Whenthe power assembly 2100 is coupled to the surgical instrument 2110, theprocessor 2104 polls the use indicator 2106 to determine when the singlepatient procedure time has expired. When the predetermined time periodhas elapsed, the processor 2104 increments the usage cycle count. Afterincrementing the usage cycle count, the processor 2104 resets the timingcircuit of the use indicator 2106.

In some instances, the use indicator 2106 comprises a time constant thatapproximates the single patient procedure time. In one embodiment, theusage cycle circuit 2102 comprises a resistor-capacitor (RC) timingcircuit 2506. The RC timing circuit comprises a time constant defined bya resistor-capacitor pair. The time constant is defined by the values ofthe resistor and the capacitor. In one embodiment, the usage cyclecircuit 2552 comprises a rechargeable battery and a clock. When thepower assembly 2100 is installed in a surgical instrument, therechargeable battery is charged by the power source. The rechargeablebattery comprises enough power to run the clock for at least the singlepatient procedure time. The clock may comprise a real time clock, aprocessor configured to implement a time function, or any other suitabletiming circuit.

Referring back to FIG. 2, in some instances, the use indicator 2106comprises a sensor configured to monitor one or more environmentalconditions experienced by the power assembly 2100. For example, the useindicator 2106 may comprise an accelerometer. The accelerometer isconfigured to monitor acceleration of the power assembly 2100. The powerassembly 2100 comprises a maximum acceleration tolerance. Accelerationabove a predetermined threshold indicates, for example, that the powerassembly 2100 has been dropped. When the use indicator 2106 detectsacceleration above the maximum acceleration tolerance, the processor2104 increments a usage cycle count. In some instances, the useindicator 2106 comprises a moisture sensor. The moisture sensor isconfigured to indicate when the power assembly 2100 has been exposed tomoisture. The moisture sensor may comprise, for example, an immersionsensor configured to indicate when the power assembly 2100 has beenfully immersed in a cleaning fluid, a moisture sensor configured toindicate when moisture is in contact with the power assembly 2100 duringuse, and/or any other suitable moisture sensor.

In some instances, the use indicator 2106 comprises a chemical exposuresensor. The chemical exposure sensor is configured to indicate when thepower assembly 2100 has come into contact with harmful and/or dangerouschemicals. For example, during a sterilization procedure, aninappropriate chemical may be used that leads to degradation of thepower assembly 2100. The processor 2104 increments the usage cycle countwhen the use indicator 2106 detects an inappropriate chemical.

In some instances, the usage cycle circuit 2102 is configured to monitorthe number of reconditioning cycles experienced by the power assembly2100. A reconditioning cycle may comprise, for example, a cleaningcycle, a sterilization cycle, a charging cycle, routine and/orpreventative maintenance, and/or any other suitable reconditioningcycle. The use indicator 2106 is configured to detect a reconditioningcycle. For example, the use indicator 2106 may comprise a moisturesensor to detect a cleaning and/or sterilization cycle. In someinstances, the usage cycle circuit 2102 monitors the number ofreconditioning cycles experienced by the power assembly 2100 anddisables the power assembly 2100 after the number of reconditioningcycles exceeds a predetermined threshold.

The usage cycle circuit 2102 may be configured to monitor the number ofpower assembly 2100 exchanges. The usage cycle circuit 2102 incrementsthe usage cycle count each time the power assembly 2100 is exchanged.When the maximum number of exchanges is exceeded the usage cycle circuit2102 locks out the power assembly 2100 and/or the surgical instrument2110. In some instances, when the power assembly 2100 is coupled thesurgical instrument 2110, the usage cycle circuit 2102 identifies theserial number of the power assembly 2100 and locks the power assembly2100 such that the power assembly 2100 is usable only with the surgicalinstrument 2110. In some instances, the usage cycle circuit 2102increments the usage cycle each time the power assembly 2100 is removedfrom and/or coupled to the surgical instrument 2110.

In some instances, the usage cycle count corresponds to sterilization ofthe power assembly 2100. The use indicator 2106 comprises a sensorconfigured to detect one or more parameters of a sterilization cycle,such as, for example, a temperature parameter, a chemical parameter, amoisture parameter, and/or any other suitable parameter. The processor2104 increments the usage cycle count when a sterilization parameter isdetected. The usage cycle circuit 2102 disables the power assembly 2100after a predetermined number of sterilizations. In some instances, theusage cycle circuit 2102 is reset during a sterilization cycle, avoltage sensor to detect a recharge cycle, and/or any suitable sensor.The processor 2104 increments the usage cycle count when areconditioning cycle is detected. The usage cycle circuit 2102 isdisabled when a sterilization cycle is detected. The usage cycle circuit2102 is reactivated and/or reset when the power assembly 2100 is coupledto the surgical instrument 2110. In some instances, the use indicatorcomprises a zero power indicator. The zero power indicator changes stateduring a sterilization cycle and is checked by the processor 2104 whenthe power assembly 2100 is coupled to a surgical instrument 2110. Whenthe zero power indicator indicates that a sterilization cycle hasoccurred, the processor 2104 increments the usage cycle count.

A counter 2108 maintains the usage cycle count. In some instances, thecounter 2108 comprises a non-volatile memory module. The processor 2104increments the usage cycle count stored in the non-volatile memorymodule each time a usage cycle is detected. The memory module may beaccessed by the processor 2104 and/or a control circuit, such as, forexample, the control circuit 2000. When the usage cycle count exceeds apredetermined threshold, the processor 2104 disables the power assembly2100. In some instances, the usage cycle count is maintained by aplurality of circuit components. For example, in one instance, thecounter 2108 comprises a resistor (or fuse) pack. After each use of thepower assembly 2100, a resistor (or fuse) is burned to an open position,changing the resistance of the resistor pack. The power assembly 2100and/or the surgical instrument 2110 reads the remaining resistance. Whenthe last resistor of the resistor pack is burned out, the resistor packhas a predetermined resistance, such as, for example, an infiniteresistance corresponding to an open circuit, which indicates that thepower assembly 2100 has reached its usage limit. In some instances, theresistance of the resistor pack is used to derive the number of usesremaining.

In some instances, the usage cycle circuit 2102 prevents further use ofthe power assembly 2100 and/or the surgical instrument 2110 when theusage cycle count exceeds a predetermined usage limit. In one instance,the usage cycle count associated with the power assembly 2100 isprovided to an operator, for example, utilizing a screen formedintegrally with the surgical instrument 2110. The surgical instrument2110 provides an indication to the operator that the usage cycle counthas exceeded a predetermined limit for the power assembly 2100, andprevents further operation of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured tophysically prevent operation when the predetermined usage limit isreached. For example, the power assembly 2100 may comprise a shieldconfigured to deploy over contacts of the power assembly 2100 when theusage cycle count exceeds the predetermined usage limit. The shieldprevents recharge and use of the power assembly 2100 by covering theelectrical connections of the power assembly 2100.

In some instances, the usage cycle circuit 2102 is located at leastpartially within the surgical instrument 2110 and is configured tomaintain a usage cycle count for the surgical instrument 2110. FIG. 22illustrates one or more components of the usage cycle circuit 2102within the surgical instrument 2110 in phantom, illustrating thealternative positioning of the usage cycle circuit 2102. When apredetermined usage limit of the surgical instrument 2110 is exceeded,the usage cycle circuit 2102 disables and/or prevents operation of thesurgical instrument 2110. The usage cycle count is incremented by theusage cycle circuit 2102 when the use indicator 2106 detects a specificevent and/or requirement, such as, for example, firing of the surgicalinstrument 2110, a predetermined time period corresponding to a singlepatient procedure time, based on one or more motor parameters of thesurgical instrument 2110, in response to a system diagnostic indicatingthat one or more predetermined thresholds are met, and/or any othersuitable requirement. As discussed above, in some instances, the useindicator 2106 comprises a timing circuit corresponding to a singlepatient procedure time. In other instances, the use indicator 2106comprises one or more sensors configured to detect a specific eventand/or condition of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured to preventoperation of the surgical instrument 2110 after the predetermined usagelimit is reached. In some instances, the surgical instrument 2110comprises a visible indicator to indicate when the predetermined usagelimit has been reached and/or exceeded. For example, a flag, such as ared flag, may pop-up from the surgical instrument 2110, such as from thehandle, to provide a visual indication to the operator that the surgicalinstrument 2110 has exceeded the predetermined usage limit. As anotherexample, the usage cycle circuit 2102 may be coupled to a display formedintegrally with the surgical instrument 2110. The usage cycle circuit2102 displays a message indicating that the predetermined usage limithas been exceeded. The surgical instrument 2110 may provide an audibleindication to the operator that the predetermined usage limit has beenexceeded. For example, in one instance, the surgical instrument 2110emits an audible tone when the predetermined usage limit is exceeded andthe power assembly 2100 is removed from the surgical instrument 2110.The audible tone indicates the last use of the surgical instrument 2110and indicates that the surgical instrument 2110 should be disposed orreconditioned.

In some instances, the usage cycle circuit 2102 is configured totransmit the usage cycle count of the surgical instrument 2110 to aremote location, such as, for example, a central database. The usagecycle circuit 2102 comprises a communications module 2112 configured totransmit the usage cycle count to the remote location. Thecommunications module 2112 may utilize any suitable communicationssystem, such as, for example, wired or wireless communications system.The remote location may comprise a central database configured tomaintain usage information. In some instances, when the power assembly2100 is coupled to the surgical instrument 2110, the power assembly 2100records a serial number of the surgical instrument 2110. The serialnumber is transmitted to the central database, for example, when thepower assembly 2100 is coupled to a charger. In some instances, thecentral database maintains a count corresponding to each use of thesurgical instrument 2110. For example, a bar code associated with thesurgical instrument 2110 may be scanned each time the surgicalinstrument 2110 is used. When the use count exceeds a predeterminedusage limit, the central database provides a signal to the surgicalinstrument 2110 indicating that the surgical instrument 2110 should bediscarded.

The surgical instrument 2110 may be configured to lock and/or preventoperation of the surgical instrument 2110 when the usage cycle countexceeds a predetermined usage limit. In some instances, the surgicalinstrument 2110 comprises a disposable instrument and is discarded afterthe usage cycle count exceeds the predetermined usage limit. In otherinstances, the surgical instrument 2110 comprises a reusable surgicalinstrument which may be reconditioned after the usage cycle countexceeds the predetermined usage limit. The surgical instrument 2110initiates a reversible lockout after the predetermined usage limit ismet. A technician reconditions the surgical instrument 2110 and releasesthe lockout, for example, utilizing a specialized technician keyconfigured to reset the usage cycle circuit 2102.

In some embodiments, the segmented circuit 2000 is configured forsequential start-up. An error check is performed by each circuit segment2002 a-2002 g prior to energizing the next sequential circuit segment2002 a-2002 g. FIG. 23 illustrates one embodiment of a process forsequentially energizing a segmented circuit 2270, such as, for example,the segmented circuit 2000. When a battery 2008 is coupled to thesegmented circuit 2000, the safety processor 2004 is energized 2272. Thesafety processor 2004 performs a self-error check 2274. When an error isdetected 2276 a, the safety processor stops energizing the segmentedcircuit 2000 and generates an error code 2278 a. When no errors aredetected 2276 b, the safety processor 2004 initiates 2278 b power-up ofthe primary processor 2006. The primary processor 2006 performs aself-error check. When no errors are detected, the primary processor2006 begins sequential power-up of each of the remaining circuitsegments 2278 b. Each circuit segment is energized and error checked bythe primary processor 2006. When no errors are detected, the nextcircuit segment is energized 2278 b. When an error is detected, thesafety processor 2004 and/or the primary process stops energizing thecurrent segment and generates an error 2278 a. The sequential start-upcontinues until all of the circuit segments 2002 a-2002 g have beenenergized. In some embodiments, the segmented circuit 2000 transitionsfrom sleep mode following a similar sequential power-up process 11250.

FIG. 24 illustrates one embodiment of a power segment 2302 comprising aplurality of daisy chained power converters 2314, 2316, 2318. The powersegment 2302 comprises a battery 2308. The battery 2308 is configured toprovide a source voltage, such as, for example, 12V. A current sensor2312 is coupled to the battery 2308 to monitor the current draw of asegmented circuit and/or one or more circuit segments. The currentsensor 2312 is coupled to an FET switch 2313. The battery 2308 iscoupled to one or more voltage converters 2309, 2314, 2316. An always onconverter 2309 provides a constant voltage to one or more circuitcomponents, such as, for example, a motion sensor 2322. The always onconverter 2309 comprises, for example, a 3.3V converter. The always onconverter 2309 may provide a constant voltage to additional circuitcomponents, such as, for example, a safety processor (not shown). Thebattery 2308 is coupled to a boost converter 2318. The boost converter2318 is configured to provide a boosted voltage above the voltageprovided by the battery 2308. For example, in the illustratedembodiment, the battery 2308 provides a voltage of 12V. The boostconverter 2318 is configured to boost the voltage to 13V. The boostconverter 2318 is configured to maintain a minimum voltage duringoperation of a surgical instrument, for example, the surgical instrument10 illustrated in FIGS. 69-71. Operation of a motor can result in thepower provided to the primary processor 2306 dropping below a minimumthreshold and creating a brownout or reset condition in the primaryprocessor 2306. The boost converter 2318 ensures that sufficient poweris available to the primary processor 2306 and/or other circuitcomponents, such as the motor controller 2343, during operation of thesurgical instrument 10. In some embodiments, the boost converter 2318 iscoupled directly one or more circuit components, such as, for example,an OLED display 2388.

The boost converter 2318 is coupled to one or more step-down convertersto provide voltages below the boosted voltage level. A first voltageconverter 2316 is coupled to the boost converter 2318 and provides afirst stepped-down voltage to one or more circuit components. In theillustrated embodiment, the first voltage converter 2316 provides avoltage of 5V. The first voltage converter 2316 is coupled to a rotaryposition encoder 2340. A FET switch 2317 is coupled between the firstvoltage converter 2316 and the rotary position encoder 2340. The FETswitch 2317 is controlled by the processor 2306. The processor 2306opens the FET switch 2317 to deactivate the position encoder 2340, forexample, during power intensive operations. The first voltage converter2316 is coupled to a second voltage converter 2314 configured to providea second stepped-down voltage. The second stepped-down voltagecomprises, for example, 3.3V. The second voltage converter 2314 iscoupled to a processor 2306. In some embodiments, the boost converter2318, the first voltage converter 2316, and the second voltage converter2314 are coupled in a daisy chain configuration. The daisy chainconfiguration allows the use of smaller, more efficient converters forgenerating voltage levels below the boosted voltage level. Theembodiments, however, are not limited to the particular voltage range(s)described in the context of this specification.

FIG. 25 illustrates one embodiment of a segmented circuit 2400configured to maximize power available for critical and/or power intensefunctions. The segmented circuit 2400 comprises a battery 2408. Thebattery 2408 is configured to provide a source voltage such as, forexample, 12V. The source voltage is provided to a plurality of voltageconverters 2409, 2418. An always-on voltage converter 2409 provides aconstant voltage to one or more circuit components, for example, amotion sensor 2422 and a safety processor 2404. The always-on voltageconverter 2409 is directly coupled to the battery 2408. The always-onconverter 2409 provides a voltage of 3.3V, for example. The embodiments,however, are not limited to the particular voltage range(s) described inthe context of this specification.

The segmented circuit 2400 comprises a boost converter 2418. The boostconverter 2418 provides a boosted voltage above the source voltageprovided by the battery 2408, such as, for example, 13V. The boostconverter 2418 provides a boosted voltage directly to one or morecircuit components, such as, for example, an OLED display 2488 and amotor controller 2443. By coupling the OLED display 2488 directly to theboost converter 2418, the segmented circuit 2400 eliminates the need fora power converter dedicated to the OLED display 2488. The boostconverter 2418 provides a boosted voltage to the motor controller 2443and the motor 2448 during one or more power intensive operations of themotor 2448, such as, for example, a cutting operation. The boostconverter 2418 is coupled to a step-down converter 2416. The step-downconverter 2416 is configured to provide a voltage below the boostedvoltage to one or more circuit components, such as, for example, 5V. Thestep-down converter 2416 is coupled to, for example, a FET switch 2451and a position encoder 2440. The FET switch 2451 is coupled to theprimary processor 2406. The primary processor 2406 opens the FET switch2451 when transitioning the segmented circuit 2400 to sleep mode and/orduring power intensive functions requiring additional voltage deliveredto the motor 2448. Opening the FET switch 2451 deactivates the positionencoder 2440 and eliminates the power draw of the position encoder 2440.The embodiments, however, are not limited to the particular voltagerange(s) described in the context of this specification.

The step-down converter 2416 is coupled to a linear converter 2414. Thelinear converter 2414 is configured to provide a voltage of, forexample, 3.3V. The linear converter 2414 is coupled to the primaryprocessor 2406. The linear converter 2414 provides an operating voltageto the primary processor 2406. The linear converter 2414 may be coupledto one or more additional circuit components. The embodiments, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

The segmented circuit 2400 comprises a bailout switch 2456. The bailoutswitch 2456 is coupled to a bailout door on the surgical instrument 10.The bailout switch 2456 and the safety processor 2404 are coupled to anAND gate 2419. The AND gate 2419 provides an input to a FET switch 2413.When the bailout switch 2456 detects a bailout condition, the bailoutswitch 2456 provides a bailout shutdown signal to the AND gate 2419.When the safety processor 2404 detects an unsafe condition, such as, forexample, due to a sensor mismatch, the safety processor 2404 provides ashutdown signal to the AND gate 2419. In some embodiments, both thebailout shutdown signal and the shutdown signal are high during normaloperation and are low when a bailout condition or an unsafe condition isdetected. When the output of the AND gate 2419 is low, the FET switch2413 is opened and operation of the motor 2448 is prevented. In someembodiments, the safety processor 2404 utilizes the shutdown signal totransition the motor 2448 to an off state in sleep mode. A third inputto the FET switch 2413 is provided by a current sensor 2412 coupled tothe battery 2408. The current sensor 2412 monitors the current drawn bythe circuit 2400 and opens the FET switch 2413 to shut-off power to themotor 2448 when an electrical current above a predetermined threshold isdetected. The FET switch 2413 and the motor controller 2443 are coupledto a bank of FET switches 2445 configured to control operation of themotor 2448.

A motor current sensor 2446 is coupled in series with the motor 2448 toprovide a motor current sensor reading to a current monitor 2447. Thecurrent monitor 2447 is coupled to the primary processor 2406. Thecurrent monitor 2447 provides a signal indicative of the current draw ofthe motor 2448. The primary processor 2406 may utilize the signal fromthe motor current 2447 to control operation of the motor, for example,to ensure the current draw of the motor 2448 is within an acceptablerange, to compare the current draw of the motor 2448 to one or moreother parameters of the circuit 2400 such as, for example, the positionencoder 2440, and/or to determine one or more parameters of a treatmentsite. In some embodiments, the current monitor 2447 may be coupled tothe safety processor 2404.

In some embodiments, actuation of one or more handle controls, such as,for example, a firing trigger, causes the primary processor 2406 todecrease power to one or more components while the handle control isactuated. For example, in one embodiment, a firing trigger controls afiring stroke of a cutting member. The cutting member is driven by themotor 2448. Actuation of the firing trigger results in forward operationof the motor 2448 and advancement of the cutting member. During firing,the primary processor 2406 closes the FET switch 2451 to remove powerfrom the position encoder 2440. The deactivation of one or more circuitcomponents allows higher power to be delivered to the motor 2448. Whenthe firing trigger is released, full power is restored to thedeactivated components, for example, by closing the FET switch 2451 andreactivating the position encoder 2440.

In some embodiments, the safety processor 2404 controls operation of thesegmented circuit 2400. For example, the safety processor 2404 mayinitiate a sequential power-up of the segmented circuit 2400, transitionof the segmented circuit 2400 to and from sleep mode, and/or mayoverride one or more control signals from the primary processor 2406.For example, in the illustrated embodiment, the safety processor 2404 iscoupled to the step-down converter 2416. The safety processor 2404controls operation of the segmented circuit 2400 by activating ordeactivating the step-down converter 2416 to provide power to theremainder of the segmented circuit 2400.

FIG. 26 illustrates one embodiment of a power system 2500 comprising aplurality of daisy chained power converters 2514, 2516, 2518 configuredto be sequentially energized. The plurality of daisy chained powerconverters 2514, 2516, 2518 may be sequentially activated by, forexample, a safety processor during initial power-up and/or transitionfrom sleep mode. The safety processor may be powered by an independentpower converter (not shown). For example, in one embodiment, when abattery voltage V_(BATT) is coupled to the power system 2500 and/or anaccelerometer detects movement in sleep mode, the safety processorinitiates a sequential start-up of the daisy chained power converters2514, 2516, 2518. The safety processor activates the 13V boost section2518. The boost section 2518 is energized and performs a self-check. Insome embodiments, the boost section 2518 comprises an integrated circuit2520 configured to boost the source voltage and to perform a self check.A diode D prevents power-up of a 5V supply section 2516 until the boostsection 2518 has completed a self-check and provided a signal to thediode D indicating that the boost section 2518 did not identify anyerrors. In some embodiments, this signal is provided by the safetyprocessor. The embodiments, however, are not limited to the particularvoltage range(s) described in the context of this specification.

The 5V supply section 2516 is sequentially powered-up after the boostsection 2518. The 5V supply section 2516 performs a self-check duringpower-up to identify any errors in the 5V supply section 2516. The 5Vsupply section 2516 comprises an integrated circuit 2515 configured toprovide a step-down voltage from the boost voltage and to perform anerror check. When no errors are detected, the 5V supply section 2516completes sequential power-up and provides an activation signal to the3.3V supply section 2514. In some embodiments, the safety processorprovides an activation signal to the 3.3V supply section 2514. The 3.3Vsupply section comprises an integrated circuit 2513 configured toprovide a step-down voltage from the 5V supply section 2516 and performa self-error check during power-up. When no errors are detected duringthe self-check, the 3.3V supply section 2514 provides power to theprimary processor. The primary processor is configured to sequentiallyenergize each of the remaining circuit segments. By sequentiallyenergizing the power system 2500 and/or the remainder of a segmentedcircuit, the power system 2500 reduces error risks, allows forstabilization of voltage levels before loads are applied, and preventslarge current draws from all hardware being turned on simultaneously inan uncontrolled manner. The embodiments, however, are not limited to theparticular voltage range(s) described in the context of thisspecification.

In one embodiment, the power system 2500 comprises an over voltageidentification and mitigation circuit. The over voltage identificationand mitigation circuit is configured to detect a monopolar returncurrent in the surgical instrument and interrupt power from the powersegment when the monopolar return current is detected. The over voltageidentification and mitigation circuit is configured to identify groundfloatation of the power system. The over voltage identification andmitigation circuit comprises a metal oxide varistor. The over voltageidentification and mitigation circuit comprises at least one transientvoltage suppression diode.

FIG. 27 illustrates one embodiment of a segmented circuit 2600comprising an isolated control section 2602. The isolated controlsection 2602 isolates control hardware of the segmented circuit 2600from a power section (not shown) of the segmented circuit 2600. Thecontrol section 2602 comprises, for example, a primary processor 2606, asafety processor (not shown), and/or additional control hardware, forexample, a FET Switch 2617. The power section comprises, for example, amotor, a motor driver, and/or a plurality of motor MOSFETS. The isolatedcontrol section 2602 comprises a charging circuit 2603 and arechargeable battery 2608 coupled to a 5V power converter 2616. Thecharging circuit 2603 and the rechargeable battery 2608 isolate theprimary processor 2606 from the power section. In some embodiments, therechargeable battery 2608 is coupled to a safety processor and anyadditional support hardware. Isolating the control section 2602 from thepower section allows the control section 2602, for example, the primaryprocessor 2606, to remain active even when main power is removed,provides a filter, through the rechargeable battery 2608, to keep noiseout of the control section 2602, isolates the control section 2602 fromheavy swings in the battery voltage to ensure proper operation evenduring heavy motor loads, and/or allows for real-time operating system(RTOS) to be used by the segmented circuit 2600. In some embodiments,the rechargeable battery 2608 provides a stepped-down voltage to theprimary processor, such as, for example, 3.3V. The embodiments, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

Use of Multiple Sensors with One Sensor Affecting a Second Sensor'sOutput or Interpretation

FIG. 28 illustrates one embodiment of an end effector 3000 comprising afirst sensor 3008 a and a second sensor 3008 b. The end effector 3000 issimilar to the end effector 300 described above. The end effector 3000comprises a first jaw member, or anvil, 3002 pivotally coupled to asecond jaw member 3004. The second jaw member 3004 is configured toreceive a staple cartridge 3006 therein. The staple cartridge 3006comprises a plurality of staples (not shown). The plurality of staplesis deployable from the staple cartridge 3006 during a surgicaloperation. The end effector 3000 comprises a first sensor 3008 a. Thefirst sensor 3008 a is configured to measure one or more parameters ofthe end effector 3000. For example, in one embodiment, the first sensor3008 a is configured to measure the gap 3010 between the anvil 3002 andthe second jaw member 3004. The first sensor 3008 a may comprise, forexample, a Hall effect sensor configured to detect a magnetic fieldgenerated by a magnet 3012 embedded in the second jaw member 3004 and/orthe staple cartridge 3006. As another example, in one embodiment, thefirst sensor 3008 a is configured to measure one or more forces exertedon the anvil 3002 by the second jaw member 3004 and/or tissue clampedbetween the anvil 3002 and the second jaw member 3004.

The end effector 3000 comprises a second sensor 3008 b. The secondsensor 3008 b is configured to measure one or more parameters of the endeffector 3000. For example, in various embodiments, the second sensor3008 b may comprise a strain gauge configured to measure the magnitudeof the strain in the anvil 3002 during a clamped condition. The straingauge provides an electrical signal whose amplitude varies with themagnitude of the strain. In various embodiments, the first sensor 3008 aand/or the second sensor 3008 b may comprise, for example, a magneticsensor such as, for example, a Hall effect sensor, a strain gauge, apressure sensor, a force sensor, an inductive sensor such as, forexample, an eddy current sensor, a resistive sensor, a capacitivesensor, an optical sensor, and/or any other suitable sensor formeasuring one or more parameters of the end effector 3000. The firstsensor 3008 a and the second sensor 3008 b may be arranged in a seriesconfiguration and/or a parallel configuration. In a seriesconfiguration, the second sensor 3008 b may be configured to directlyaffect the output of the first sensor 3008 a. In a parallelconfiguration, the second sensor 3008 b may be configured to indirectlyaffect the output of the first sensor 3008 a.

In one embodiment, the one or more parameters measured by the firstsensor 3008 a are related to the one or more parameters measured by thesecond sensor 3008 b. For example, in one embodiment, the first sensor3008 a is configured to measure the gap 3010 between the anvil 3002 andthe second jaw member 3004. The gap 3010 is representative of thethickness and/or compressibility of a tissue section clamped between theanvil 3002 and the staple cartridge 3006. The first sensor 3008 a maycomprise, for example, a Hall effect sensor configured to detect amagnetic field generated by a magnet 3012 coupled to the second jawmember 3004 and/or the staple cartridge 3006. Measuring at a singlelocation accurately describes the compressed tissue thickness for acalibrated full bit of tissue, but may provide inaccurate results when apartial bite of tissue is placed between the anvil 3002 and the secondjaw member 3004. A partial bite of tissue, either a proximal partialbite or a distal partial bite, changes the clamping geometry of theanvil 3002.

In some embodiments, the second sensor 3008 b is configured to detectone or more parameters indicative of a type of tissue bite, for example,a full bite, a partial proximal bite, and/or a partial distal bite. Themeasurement of the second sensor 3008 b may be used to adjust themeasurement of the first sensor 3008 a to accurately represent aproximal or distal positioned partial bite's true compressed tissuethickness. For example, in one embodiment, the second sensor 3008 bcomprises a strain gauge, such as, for example, a micro-strain gauge,configured to monitor the amplitude of the strain in the anvil during aclamped condition. The amplitude of the strain of the anvil 3002 is usedto modify the output of the first sensor 3008 a, for example, a Halleffect sensor, to accurately represent a proximal or distal positionedpartial bite's true compressed tissue thickness. The first sensor 3008 aand the second sensor 3008 b may be measured in real-time during aclamping operation. Real-time measurement allows time based informationto be analyzed, for example, by the primary processor 2006, and used toselect one or more algorithms and/or look-up tables to recognize tissuecharacteristics and clamping positioning to dynamically adjust tissuethickness measurements.

In some embodiments, the thickness measurement of the first sensor 3008a may be provided to an output device of a surgical instrument 10coupled to the end effector 3000. For example, in one embodiment, theend effector 3000 is coupled to the surgical instrument 10 comprising adisplay 2028. The measurement of the first sensor 3008 a is provided toa processor, for example, the primary processor 2006. The primaryprocessor 2006 adjusts the measurement of the first sensor 3008 a basedon the measurement of the second sensor 3008 b to reflect the truetissue thickness of a tissue section clamped between the anvil 3002 andthe staple cartridge 3006. The primary processor 2006 outputs theadjusted tissue thickness measurement and an indication of full orpartial bite to the display 2028. An operator may determine whether ornot to deploy the staples in the staple cartridge 3006 based on thedisplayed values.

In some embodiments, the first sensor 3008 a and the second sensor 3008b may be located in different environments, such as, for example, thefirst sensor 3008 a being located within a patient at a treatment siteand the second sensor 3008 b being located externally to the patient.The second sensor 3008 b may be configured to calibrate and/or modifythe output of the first sensor 3008 a. The first sensor 3008 a and/orthe second sensor 3008 b may comprise, for example, an environmentalsensor. Environmental sensors may comprise, for example, temperaturesensors, humidity sensors, pressure sensors, and/or any other suitableenvironmental sensor.

FIG. 29 is a logic diagram illustrating one embodiment of a process 3020for adjusting the measurement of a first sensor 3008 a based on inputfrom a second sensor 3008 b. A first signal is captured 3022 a by thefirst sensor 3008 a. The first signal 3022 a may be conditioned based onone or more predetermined parameters, such as, for example, a smoothingfunction, a look-up table, and/or any other suitable conditioningparameters. A second signal is captured 3022 b by the second sensor 3008b. The second signal 3022 b may be conditioned based on one or morepredetermined conditioning parameters. The first signal 3022 a and thesecond signal 3022 b are provided to a processor, such as, for example,the primary processor 2006. The processor 2006 adjusts the measurementof the first sensor 3022 a, as represented by the first signal 3022 a,based on the second signal 3022 b from the second sensor. For example,in one embodiment, the first sensor 3022 a comprises a Hall effectsensor and the second sensor 3022 b comprises a strain gauge. Thedistance measurement of the first sensor 3022 a is adjusted by theamplitude of the strain measured by the second sensor 3022 b todetermine the fullness of the bite of tissue in the end effector 3000.The adjusted measurement is displayed 3026 to an operator by, forexample, a display 2026 embedded in the surgical instrument 10.

FIG. 30 is a logic diagram illustrating one embodiment of a process 3030for determining a look-up table for a first sensor 3008 a based on theinput from a second sensor 3008 b. The first sensor 3008 a captures 3022a a signal indicative of one or more parameters of the end effector3000. The first signal 3022 a may be conditioned based on one or morepredetermined parameters, such as, for example, a smoothing function, alook-up table, and/or any other suitable conditioning parameters. Asecond signal is captured 3022 b by the second sensor 3008 b. The secondsignal 3022 b may be conditioned based on one or more predeterminedconditioning parameters. The first signal 3022 a and the second signal3022 b are provided to a processor, such as, for example, the primaryprocessor 2006. The processor 2006 selects a look-up table from one ormore available look-up tables 3034 a, 3034 b based on the value of thesecond signal. The selected look-up table is used to convert the firstsignal into a thickness measurement of the tissue located between theanvil 3002 and the staple cartridge 3006. The adjusted measurement isdisplayed 3026 to an operator by, for example, a display 2026 embeddedin the surgical instrument 10.

FIG. 31 is a logic diagram illustrating one embodiment of a process 3040for calibrating a first sensor 3008 a in response to an input from asecond sensor 3008 b. The first sensor 3008 a is configured to capture3022 a a signal indicative of one or more parameters of the end effector3000. The first signal 3022 a may be conditioned based on one or morepredetermined parameters, such as, for example, a smoothing function, alook-up table, and/or any other suitable conditioning parameters. Asecond signal is captured 3022 b by the second sensor 3008 b. The secondsignal 3022 b may be conditioned based on one or more predeterminedconditioning parameters. The first signal 3022 a and the second signal3022 b are provided to a processor, such as, for example, the primaryprocessor 2006. The primary processor 2006 calibrates 3042 the firstsignal 3022 a in response to the second signal 3022 b. The first signal3022 a is calibrated 3042 to reflect the fullness of the bite of tissuein the end effector 3000. The calibrated signal is displayed 3026 to anoperator by, for example, a display 2026 embedded in the surgicalinstrument 10.

FIG. 32A is a logic diagram illustrating one embodiment of a process3050 for determining and displaying the thickness of a tissue sectionclamped between the anvil 3002 and the staple cartridge 3006 of the endeffector 3000. The process 3050 comprises obtaining a Hall effectvoltage 3052, for example, through a Hall effect sensor located at thedistal tip of the anvil 3002. The Hall effect voltage 3052 is providedto an analog to digital convertor 3054 and converted into a digitalsignal. The digital signal is provided to a processor, such as, forexample, the primary processor 2006. The primary processor 2006calibrates 3056 the curve input of the Hall effect voltage 3052 signal.A strain gauge 3058, such as, for example, a micro-strain gauge, isconfigured to measure one or more parameters of the end effector 3000,such as, for example, the amplitude of the strain exerted on the anvil3002 during a clamping operation. The measured strain is converted 3060to a digital signal and provided to the processor, such as, for example,the primary processor 2006. The primary processor 2006 uses one or morealgorithms and/or lookup tables to adjust the Hall effect voltage 3052in response to the strain measured by the strain gauge 3058 to reflectthe true thickness and fullness of the bite of tissue clamped by theanvil 3002 and the staple cartridge 3006. The adjusted thickness isdisplayed 3026 to an operator by, for example, a display 2026 embeddedin the surgical instrument 10.

In some embodiments, the surgical instrument can further comprise a loadcell or sensor 3082. The load sensor 3082 can be located, for instance,in the shaft assembly 200, described above, or in the housing 12, alsodescribed above. FIG. 32B is a logic diagram illustrating one embodimentof a process 3070 for determining and displaying the thickness of atissue section clamped between the anvil 3002 and the staple cartridge3006 of the end effector 3000. The process comprises obtaining a Halleffect voltage 3072, for example, through a Hall effect sensor locatedat the distal tip of the anvil 3002. The Hall effect voltage 3072 isprovided to an analog to digital convertor 3074 and converted into adigital signal. The digital signal is provided to a processor, such as,for example, the primary processor 2006. The primary processor 2006applies calibrates 3076 the curve input of the Hall effect voltage 3072signal. A strain gauge 3078, such as, for example, a micro-strain gauge,is configured to measure one or more parameters of the end effector3000, such as, for example, the amplitude of the strain exerted on theanvil 3002 during a clamping operation. The measured strain is converted3080 to a digital signal and provided to the processor, such as, forexample, the primary processor 2006. The load sensor 3082 measures theclamping force of the anvil 3002 against the staple cartridge 3006. Themeasured clamping force is converted 3084 to a digital signal andprovided to the processor, such as for example, the primary processor2006. The primary processor 2006 uses one or more algorithms and/orlookup tables to adjust the Hall effect voltage 3072 in response to thestrain measured by the strain gauge 3078 and the clamping force measuredby the load sensor 3082 to reflect the true thickness and fullness ofthe bite of tissue clamped by the anvil 3002 and the staple cartridge3006. The adjusted thickness is displayed 3026 to an operator by, forexample, a display 2026 embedded in the surgical instrument 10.

FIG. 33 is a graph 3090 illustrating an adjusted Hall effect thicknessmeasurement 3094 compared to an unmodified Hall effect thicknessmeasurement 3092. As shown in FIG. 33, the unmodified Hall effectthickness measurement 3092 indicates a thicker tissue measurement, asthe single sensor is unable to compensate for partial distal/proximalbites that result in incorrect thickness measurements. The adjustedthickness measurement 3094 is generated by, for example, the process3050 illustrated in FIG. 32A. The Hall effect thickness measurement 3092is calibrated based on input from one or more additional sensors, suchas, for example, a strain gauge. The adjusted Hall effect thickness 3094reflects the true thickness of the tissue located between an anvil 3002and a staple cartridge 3006.

FIG. 34 illustrates one embodiment of an end effector 3100 comprising afirst sensor 3108 a and a second sensor 3108 b. The end effector 3100 issimilar to the end effector 3000 illustrated in FIG. 28. The endeffector 3100 comprises a first jaw member, or anvil, 3102 pivotallycoupled to a second jaw member 3104. The second jaw member 3104 isconfigured to receive a staple cartridge 3106 therein. The end effector3100 comprises a first sensor 3108 a coupled to the anvil 3102. Thefirst sensor 3108 a is configured to measure one or more parameters ofthe end effector 3100, such as, for example, the gap 3110 between theanvil 3102 and the staple cartridge 3106. The gap 3110 may correspondto, for example, a thickness of tissue clamped between the anvil 3102and the staple cartridge 3106. The first sensor 3108 a may comprise anysuitable sensor for measuring one or more parameters of the endeffector. For example, in various embodiments, the first sensor 3108 amay comprise a magnetic sensor, such as a Hall effect sensor, a straingauge, a pressure sensor, an inductive sensor, such as an eddy currentsensor, a resistive sensor, a capacitive sensor, an optical sensor,and/or any other suitable sensor.

In some embodiments, the end effector 3100 comprises a second sensor3108 b. The second sensor 3108 b is coupled to second jaw member 3104and/or the staple cartridge 3106. The second sensor 3108 b is configuredto detect one or more parameters of the end effector 3100. For example,in some embodiments, the second sensor 3108 b is configured to detectone or more instrument conditions such as, for example, a color of thestaple cartridge 3106 coupled to the second jaw member 3104, a length ofthe staple cartridge 3106, a clamping condition of the end effector3100, the number of uses/number of remaining uses of the end effector3100 and/or the staple cartridge 3106, and/or any other suitableinstrument condition. The second sensor 3108 b may comprise any suitablesensor for detecting one or more instrument conditions, such as, forexample, a magnetic sensor, such as a Hall effect sensor, a straingauge, a pressure sensor, an inductive sensor, such as an eddy currentsensor, a resistive sensor, a capacitive sensor, an optical sensor,and/or any other suitable sensor.

The end effector 3100 may be used in conjunction with any of theprocesses shown in FIGS. 29-33. For example, in one embodiment, inputfrom the second sensor 3108 b may be used to calibrate the input of thefirst sensor 3108 a. The second sensor 3108 b may be configured todetect one or more parameters of the staple cartridge 3106, such as, forexample, the color and/or length of the staple cartridge 3106. Thedetected parameters, such as the color and/or the length of the staplecartridge 3106, may correspond to one or more properties of thecartridge, such as, for example, the height of the cartridge deck, thethickness of tissue useable/optimal for the staple cartridge, and/or thepattern of the staples in the staple cartridge 3106. The knownparameters of the staple cartridge 3106 may be used to adjust thethickness measurement provided by the first sensor 3108 a. For example,if the staple cartridge 3106 has a higher deck height, the thicknessmeasurement provided by the first sensor 3108 a may be reduced tocompensate for the added deck height. The adjusted thickness may bedisplayed to an operator, for example, through a display 2026 coupled tothe surgical instrument 10.

FIG. 35 illustrates one embodiment of an end effector 3150 comprising afirst sensor 3158 and a plurality of second sensors 3160 a, 3160 b. Theend effector 3150 comprises a first jaw member, or anvil, 3152 and asecond jaw member 3154. The second jaw member 3154 is configured toreceive a staple cartridge 3156. The anvil 3152 is pivotally moveablewith respect to the second jaw member 3154 to clamp tissue between theanvil 3152 and the staple cartridge 3156. The anvil comprises a firstsensor 3158. The first sensor 3158 is configured to detect one or moreparameters of the end effector 3150, such as, for example, the gap 3110between the anvil 3152 and the staple cartridge 3156. The gap 3110 maycorrespond to, for example, a thickness of tissue clamped between theanvil 3152 and the staple cartridge 3156. The first sensor 3158 maycomprise any suitable sensor for measuring one or more parameters of theend effector. For example, in various embodiments, the first sensor 3158may comprise a magnetic sensor, such as a Hall effect sensor, a straingauge, a pressure sensor, an inductive sensor, such as an eddy currentsensor, a resistive sensor, a capacitive sensor, an optical sensor,and/or any other suitable sensor.

In some embodiments, the end effector 3150 comprises a plurality ofsecondary sensors 3160 a, 3160 b. The secondary sensors 3160 a, 3160 bare configured to detect one or more parameters of the end effector3150. For example, in some embodiments, the secondary sensors 3160 a,3160 b are configured to measure an amplitude of strain exerted on theanvil 3152 during a clamping procedure. In various embodiments, thesecondary sensors 3160 a, 3160 b may comprise a magnetic sensor, such asa Hall effect sensor, a strain gauge, a pressure sensor, an inductivesensor, such as an eddy current sensor, a resistive sensor, a capacitivesensor, an optical sensor, and/or any other suitable sensor. Thesecondary sensors 3160 a, 3160 b may be configured to measure one ormore identical parameters at different locations of the anvil 3152,different parameters at identical locations on the anvil 3152, and/ordifferent parameters at different locations on the anvil 3152.

FIG. 36 is a logic diagram illustrating one embodiment of a process 3170for adjusting a measurement of a first sensor 3158 in response to aplurality of secondary sensors 3160 a, 3160. In one embodiment, a Halleffect voltage is obtained 3172, for example, by a Hall effect sensor.The Hall effect voltage is converted 3174 by an analog to digitalconvertor. The converted Hall effect voltage signal is calibrated 3176.The calibrated curve represents the thickness of a tissue sectionlocated between the anvil 3152 and the staple cartridge 3156. Aplurality of secondary measurements are obtained 3178 a, 3178 b by aplurality of secondary sensors, such as, for example, a plurality ofstrain gauges. The input of the strain gauges is converted 3180 a, 3180b into one or more digital signals, for example, by a plurality ofelectronic pStrain conversion circuits. The calibrated Hall effectvoltage and the plurality of secondary measurements are provided to aprocessor, such as, for example, the primary processor 2006.

The primary processor utilizes the secondary measurements to adjust 3182the Hall effect voltage, for example, by applying an algorithm and/orutilizing one or more look-up tables. The adjusted Hall effect voltagerepresents the true thickness and fullness of the bite of tissue clampedby the anvil 3152 and the staple cartridge 3156. The adjusted thicknessis displayed 3026 to an operator by, for example, a display 2026embedded in the surgical instrument 10.

FIG. 37 illustrates one embodiment of a circuit 3190 configured toconvert signals from the first sensor 3158 and the plurality ofsecondary sensors 3160 a, 3160 b into digital signals receivable by aprocessor, such as, for example, the primary processor 2006. The circuit3190 comprises an analog-to-digital convertor 3194. In some embodiments,the analog-to-digital convertor 3194 comprises a 4-channel, 18-bitanalog to digital convertor. Those skilled in the art will recognizethat the analog-to-digital convertor 3194 may comprise any suitablenumber of channels and/or bits to convert one or more inputs from analogto digital signals. The circuit 3190 comprises one or more levelshifting resistors 3196 configured to receive an input from the firstsensor 3158, such as, for example, a Hall effect sensor. The levelshifting resistors 3196 adjust the input from the first sensor, shiftingthe value to a higher or lower voltage depending on the input. The levelshifting resistors 3196 provide the level-shifted input from the firstsensor 3158 to the analog-to-digital convertor.

In some embodiments, a plurality of secondary sensors 3160 a, 3160 b arecoupled to a plurality of bridges 3192 a, 3192 b within the circuit3190. The plurality of bridges 3192 a, 3192 b may provide filtering ofthe input from the plurality of secondary sensors 3160 a, 3160 b. Afterfiltering the input signals, the plurality of bridges 3192 a, 3192 bprovide the inputs from the plurality of secondary sensors 3160 a, 3160b to the analog-to-digital convertor 3194. In some embodiments, a switch3198 coupled to one or more level shifting resistors may be coupled tothe analog-to-digital convertor 3194. The switch 3198 is configured tocalibrate one or more of the input signals, such as, for example, aninput from a Hall effect sensor. The switch 3198 may be engaged toprovide one or more level shifting signals to adjust the input of one ormore of the sensors, such as, for example, to calibrate the input of aHall effect sensor. In some embodiments, the adjustment is notnecessary, and the switch 3198 is left in the open position to decouplethe level shifting resistors. The switch 3198 is coupled to theanalog-to-digital convertor 3194. The analog-to-digital convertor 3194provides an output to one or more processors, such as, for example, theprimary processor 2006. The primary processor 2006 calculates one ormore parameters of the end effector 3150 based on the input from theanalog-to-digital convertor 3194. For example, in one embodiment, theprimary processor 2006 calculates a thickness of tissue located betweenthe anvil 3152 and the staple cartridge 3156 based on input from one ormore sensors 3158, 3160 a, 3160 b.

FIG. 38 illustrates one embodiment of an end effector 3200 comprising aplurality of sensors 3208 a-3208 d. The end effector 3200 comprises ananvil 3202 pivotally coupled to a second jaw member 3204. The second jawmember 3204 is configured to receive a staple cartridge 3206 therein.The anvil 3202 comprises a plurality of sensors 3208 a-3208 d thereon.The plurality of sensors 3208 a-3208 d is configured to detect one ormore parameters of the end effector 3200, such as, for example, theanvil 3202. The plurality of sensors 3208 a-3208 d may comprise one ormore identical sensors and/or different sensors. The plurality ofsensors 3208 a-3208 d may comprise, for example, magnetic sensors, suchas a Hall effect sensor, strain gauges, pressure sensors, inductivesensors, such as an eddy current sensor, resistive sensors, capacitivesensors, optical sensors, and/or any other suitable sensors orcombination thereof. For example, in one embodiment, the plurality ofsensors 3208 a-3208 d may comprise a plurality of strain gauges.

In one embodiment, the plurality of sensors 3208 a-3208 d allows arobust tissue thickness sensing process to be implemented. By detectingvarious parameters along the length of the anvil 3202, the plurality ofsensors 3208 a-3208 d allow a surgical instrument, such as, for example,the surgical instrument 10, to calculate the tissue thickness in thejaws regardless of the bite, for example, a partial or full bite. Insome embodiments, the plurality of sensors 3208 a-3208 d comprises aplurality of strain gauges. The plurality of strain gauges is configuredto measure the strain at various points on the anvil 3202. The amplitudeand/or the slope of the strain at each of the various points on theanvil 3202 can be used to determine the thickness of tissue in betweenthe anvil 3202 and the staple cartridge 3206. The plurality of straingauges may be configured to optimize maximum amplitude and/or slopedifferences based on clamping dynamics to determine thickness, tissueplacement, and/or material properties of the tissue. Time basedmonitoring of the plurality of sensors 3208 a-3208 d during clampingallows a processor, such as, for example, the primary processor 2006, toutilize algorithms and look-up tables to recognize tissuecharacteristics and clamping positions and dynamically adjust the endeffector 3200 and/or tissue clamped between the anvil 3202 and thestaple cartridge 3206.

FIG. 39 is a logic diagram illustrating one embodiment of a process 3220for determining one or more tissue properties based on a plurality ofsensors 3208 a-3208 d. In one embodiment, a plurality of sensors 3208a-3208 d generate 3222 a-3222 d a plurality of signals indicative of oneor more parameters of the end effector 3200. The plurality of generatedsignals is converted 3224 a-3224 d to digital signals and provided to aprocessor. For example, in one embodiment comprising a plurality ofstrain gauges, a plurality of electronic pStrain (micro-strain)conversion circuits convert 3224 a-3224 d the strain gauge signals todigital signals. The digital signals are provided to a processor, suchas, for example, the primary processor 2006. The primary processor 2006determines 3226 one or more tissue characteristics based on theplurality of signals. The processor 2006 may determine the one or moretissue characteristics by applying an algorithm and/or a look-up table.The one or more tissue characteristics are displayed 3026 to anoperator, for example, by a display 2026 embedded in the surgicalinstrument 10.

FIG. 40 illustrates one embodiment of an end effector 3250 comprising aplurality of sensors 3260 a-3260 d coupled to a second jaw member 3254.The end effector 3250 comprises an anvil 3252 pivotally coupled to asecond jaw member 3254. The anvil 3252 is moveable relative to thesecond jaw member 3254 to clamp one or more materials, such as, forexample, a tissue section 3264, therebetween. The second jaw member 3254is configured to receive a staple cartridge 3256. A first sensor 3258 iscoupled to the anvil 3252. The first sensor is configured to detect oneor more parameters of the end effector 3150, such as, for example, thegap 3110 between the anvil 3252 and the staple cartridge 3256. The gap3110 may correspond to, for example, a thickness of tissue clampedbetween the anvil 3252 and the staple cartridge 3256. The first sensor3258 may comprise any suitable sensor for measuring one or moreparameters of the end effector. For example, in various embodiments, thefirst sensor 3258 may comprise a magnetic sensor, such as a Hall effectsensor, a strain gauge, a pressure sensor, an inductive sensor, such asan eddy current sensor, a resistive sensor, a capacitive sensor, anoptical sensor, and/or any other suitable sensor.

A plurality of secondary sensors 3260 a-3260 d is coupled to the secondjaw member 3254. The plurality of secondary sensors 3260 a-3260 d may beformed integrally with the second jaw member 3254 and/or the staplecartridge 3256. For example, in one embodiment, the plurality ofsecondary sensors 3260 a-3260 d is disposed on an outer row of thestaple cartridge 3256 (see FIG. 41). The plurality of secondary sensors3260 a-3260 d are configured to detect one or more parameters of the endeffector 3250 and/or a tissue section 3264 clamped between the anvil3252 and the staple cartridge 3256. The plurality of secondary sensors3260 a-3260 d may comprise any suitable sensors for detecting one ormore parameters of the end effector 3250 and/or the tissue section 3264,such as, for example, magnetic sensors, such as a Hall effect sensor,strain gauges, pressure sensors, inductive sensors, such as an eddycurrent sensor, resistive sensors, capacitive sensors, optical sensors,and/or any other suitable sensors or combination thereof. The pluralityof secondary sensors 3260 a-3260 d may comprise identical sensors and/ordifferent sensors.

In some embodiments, the plurality of secondary sensors 3260 a-3260 dcomprises dual purpose sensors and tissue stabilizing elements. Theplurality of secondary sensors 3260 a-3260 d comprise electrodes and/orsensing geometries configured to create a stabilized tissue conditionwhen the plurality of secondary sensors 3260 a-3260 d are engaged with atissue section 3264, such as, for example, during a clamping operation.In some embodiments, one or more of the plurality of secondary sensors3260 a-3260 d may be replaced with non-sensing tissue stabilizingelements. The secondary sensors 3260 a-3260 d create a stabilized tissuecondition by controlling tissue flow, staple formation, and/or othertissue conditions during a clamping, stapling, and/or other treatmentprocess.

FIG. 41 illustrates one embodiment of a staple cartridge 3270 comprisinga plurality of sensors 3272 a-3272 h formed integrally therein. Thestaple cartridge 3270 comprises a plurality of rows containing aplurality of holes for storing staples therein. One or more of the holesin the outer row 3278 are replaced with one of the plurality of sensors3272 a-3272 h. A cut-away section 3274 is shown to illustrate a sensor3272 f coupled to a sensor wire 3276 b. The sensor wires 3276 a, 3276 bmay comprise a plurality of wires for coupling the plurality of sensors3272 a-3272 h to one or more circuits of a surgical instrument, such as,for example, the surgical instrument 10. In some embodiments, one ormore of the plurality of sensors 3272 a-3272 h comprise dual purposesensor and tissue stabilizing elements having electrodes and/or sensinggeometries configured to provide tissue stabilization. In someembodiments, the plurality of sensors 3272 a-3272 h may be replaced withand/or co-populated with a plurality of tissue stabilizing elements.Tissue stabilization may be provided by, for example, controlling tissueflow and/or staple formation during a clamping and/or stapling process.The plurality of sensors 3272 a-3272 h provide signals to one or morecircuits of the surgical instrument 10 to enhance feedback of staplingperformance and/or tissue thickness sensing.

FIG. 42 is a logic diagram illustrating one embodiment of a process 3280for determining one or more parameters of a tissue section 3264 clampedwithin an end effector, such as, for example, the end effector 3250illustrated in FIG. 40. In one embodiment, a first sensor 3258 isconfigured to detect one or more parameters of the end effector 3250and/or a tissue section 3264 located between the anvil 3252 and thestaple cartridge 3256. A first signal is generated 3282 by the firstsensors 3258. The first signal is indicative of the one or moreparameters detected by the first sensor 3258. One or more secondarysensors 3260 are configured to detect one or more parameters of the endeffector 3250 and/or the tissue section 3264. The secondary sensors 3260may be configured to detect the same parameters, additional parameters,or different parameters as the first sensor 3258. Secondary signals 3284are generated by the secondary sensors 3260. The secondary signals 3284are indicative of the one or more parameters detected by the secondarysensors 3260. The first signal and the secondary signals are provided toa processor, such as, for example, a primary processor 2006. Theprocessor 2006 adjusts 3286 the first signal generated by the firstsensor 3258 based on input generated by the secondary sensors 3260. Theadjusted signal may be indicative of, for example, the true thickness ofa tissue section 3264 and the fullness of the bite. The adjusted signalis displayed 3026 to an operator by, for example, a display 2026embedded in the surgical instrument 10.

FIG. 43 illustrates one embodiment of an end effector 3300 comprising aplurality of redundant sensors 3308 a, 3308 b. The end effector 3300comprises a first jaw member, or anvil, 3302 pivotally coupled to asecond jaw member 3304. The second jaw member 3304 is configured toreceive a staple cartridge 3306 therein. The anvil 3302 is moveable withrespect to the staple cartridge 3306 to grasp a material, such as, forexample, a tissue section, between the anvil 3302 and the staplecartridge 3306. A plurality of sensors 3308 a, 3308 b is coupled to theanvil. The plurality of sensors 3308 a, 3308 b are configured to detectone or more parameters of the end effector 3300 and/or a tissue sectionlocated between the anvil 3302 and the staple cartridge 3306. In someembodiments, the plurality of sensors 3308 a, 3308 b are configured todetect a gap 3310 between the anvil 3302 and the staple cartridge 3306.The gap 3310 may correspond to, for example, the thickness of tissuelocated between the anvil 3302 and the staple cartridge 3306. Theplurality of sensors 3308 a, 3308 b may detect the gap 3310 by, forexample, detecting a magnetic field generated by a magnet 3312 coupledto the second jaw member 3304.

In some embodiments, the plurality of sensors 3308 a, 3308 b compriseredundant sensors. The redundant sensors are configured to detect thesame properties of the end effector 3300 and/or a tissue section locatedbetween the anvil 3302 and the staple cartridge 3306. The redundantsensors may comprise, for example, Hall effect sensors configured todetect the gap 3310 between the anvil 3302 and the staple cartridge3306. The redundant sensors provide signals representative of one ormore parameters allowing a processor, such as, for example, the primaryprocessor 2006, to evaluate the multiple inputs and determine the mostreliable input. In some embodiments, the redundant sensors are used toreduce noise, false signals, and/or drift. Each of the redundant sensorsmay be measured in real-time during clamping, allowing time-basedinformation to be analyzed and algorithms and/or look-up tables torecognize tissue characteristics and clamping positioning dynamically.The input of one or more of the redundant sensors may be adjusted and/orselected to identify the true tissue thickness and bite of a tissuesection located between the anvil 3302 and the staple cartridge 3306.

FIG. 44 is a logic diagram illustrating one embodiment of a process 3320for selecting the most reliable output from a plurality of redundantsensors, such as, for example, the plurality of sensors 3308 a, 3308 billustrated in FIG. 43. In one embodiment, a first signal is generatedby a first sensor 3308 a. The first signal is converted 3322 a by ananalog-to-digital convertor. One or more additional signals aregenerated by one or more redundant sensors 3308 b. The one or moreadditional signals are converted 3322 b by an analog-to-digitalconvertor. The converted signals are provided to a processor, such as,for example, the primary processor 2006. The primary processor evaluates3324 the redundant inputs to determine the most reliable output. Themost reliable output may be selected based on one or more parameters,such as, for example, algorithms, look-up tables, input from additionalsensors, and/or instrument conditions. After selecting the most reliableoutput, the processor may adjust the output based on one or moreadditional sensors to reflect, for example, the true thickness and biteof a tissue section located between the anvil 3302 and the staplecartridge 3306. The adjusted most reliable output is displayed 3026 toan operator by, for example, a display 2026 embedded in the surgicalinstrument 10.

FIG. 45 illustrates one embodiment of an end effector 3350 comprising asensor 3358 comprising a specific sampling rate to limit or eliminatefalse signals. The end effector 3350 comprises a first jaw member, oranvil, 3352 pivotably coupled to a second jaw member 3354. The secondjaw member 3354 is configured to receive a staple cartridge 3356therein. The staple cartridge 3356 contains a plurality of staples thatmay be delivered to a tissue section located between the anvil 3352 andthe staple cartridge 3356. A sensor 3358 is coupled to the anvil 3352.The sensor 3358 is configured to detect one or more parameters of theend effector 3350, such as, for example, the gap 3364 between the anvil3352 and the staple cartridge 3356. The gap 3364 may correspond to thethickness of a material, such as, for example, a tissue section, and/orthe fullness of a bite of material located between the anvil 3352 andthe staple cartridge 3356. The sensor 3358 may comprise any suitablesensor for detecting one or more parameters of the end effector 3350,such as, for example, a magnetic sensor, such as a Hall effect sensor, astrain gauge, a pressure sensor, an inductive sensor, such as an eddycurrent sensor, a resistive sensor, a capacitive sensor, an opticalsensor, and/or any other suitable sensor.

In one embodiment, the sensor 3358 comprises a magnetic sensorconfigured to detect a magnetic field generated by an electromagneticsource 3360 coupled to the second jaw member 3354 and/or the staplecartridge 3356. The electromagnetic source 3360 generates a magneticfield detected by the sensor 3358. The strength of the detected magneticfield may correspond to, for example, the thickness and/or fullness of abite of tissue located between the anvil 3352 and the staple cartridge3356. In some embodiments, the electromagnetic source 3360 generates asignal at a known frequency, such as, for example, 1 MHz. In otherembodiments, the signal generated by the electromagnetic source 3360 maybe adjustable based on, for example, the type of staple cartridge 3356installed in the second jaw member 3354, one or more additional sensor,an algorithm, and/or one or more parameters.

In one embodiment, a signal processor 3362 is coupled to the endeffector 3350, such as, for example, the anvil 3352. The signalprocessor 3362 is configured to process the signal generated by thesensor 3358 to eliminate false signals and to boost the input from thesensor 3358. In some embodiments, the signal processor 3362 may belocated separately from the end effector 3350, such as, for example, inthe handle 14 of a surgical instrument 10. In some embodiments, thesignal processor 3362 is formed integrally with and/or comprises analgorithm executed by a general processor, such as, for example, theprimary processor 2006. The signal processor 3362 is configured toprocess the signal from the sensor 3358 at a frequency substantiallyequal to the frequency of the signal generated by the electromagneticsource 3360. For example, in one embodiment, the electromagnetic source3360 generates a signal at a frequency of 1 MHz. The signal is detectedby the sensor 3358. The sensor 3358 generates a signal indicative of thedetected magnetic field which is provided to the signal processor 3362.The signal is processed by the signal processor 3362 at a frequency of1MHz to eliminate false signals. The processed signal is provided to aprocessor, such as, for example, the primary processor 2006. The primaryprocessor 2006 correlates the received signal to one or more parametersof the end effector 3350, such as, for example, the gap 3364 between theanvil 3352 and the staple cartridge 3356.

FIG. 46 is a logic diagram illustrating one embodiment of a process 3370for generating a thickness measurement for a tissue section locatedbetween an anvil and a staple cartridge of an end effector, such as, forexample, the end effector 3350 illustrated in FIG. 45. In one embodimentof the process 3370, a signal is generated 3372 by a modulatedelectromagnetic source 3360. The generated signal may comprise, forexample, a 1 MHz signal. A magnetic sensor 3358 is configured to detect3374 the signal generated by the electromagnetic source 3360. Themagnetic sensor 3358 generates a signal indicative of the detectedmagnetic field and provides the signal to a signal processor 3362. Thesignal processor 3362 processes 3376 the signal to remove noise, falsesignals, and/or to boost the signal. The processed signal is provided toan analog-to-digital convertor for conversion 3378 to a digital signal.The digital signal may be calibrated 3380, for example, by applicationof a calibration curve input algorithm and/or look-up table. The signalprocessing 3376, conversion 3378, and calibration 3380 may be performedby one or more circuits. The calibrated signal is displayed 3026 to auser by, for example, a display 2026 formed integrally with a surgicalinstrument 10.

Although the various embodiments so far described comprise an endeffector having first and second jaw members pivotally coupled, thedescribed embodiments are not so limited. For example, in oneembodiment, the end effector may comprise a circular stapler endeffector. FIG. 47 illustrates one embodiment of a circular stapler 3400configured to implement one or more of the processes described in FIGS.28-46. The circular stapler 3400 comprises a body 3402. The body 3402may be coupled to a shaft, such as, for example, the shaft assembly 200of the surgical instrument 10. The body 3402 is configured to receive astaple cartridge and/or one or more staples therein (not shown). Ananvil 3404 is moveably coupled to the body 3402. The anvil 3404 may becoupled to the body 3402 by, for example, a shaft 3406. The shaft 3406is receivable within a cavity within the body (not shown). In someembodiments, a breakaway washer 3408 is coupled to the anvil 3404. Thebreakaway washer 3408 may comprise a buttress or reinforcing materialduring stapling.

In some embodiments, the circular stapler 3400 comprises a plurality ofsensors 3410 a, 3410 b. The plurality of sensor 3410 a, 3410 b isconfigured to detect one or more parameters of the circular stapler 3400and/or a tissue section located between the body 3402 and the anvil3404. The plurality of sensors 3410 a, 3410 b may be coupled to anysuitable portion of the anvil 3404, such as, for example, beingpositioned under the breakaway washer 3408. The plurality of sensors3410 a, 3410 b may be arranged in any suitable arrangement, such as, forexample, being equally spaced about the perimeter of the anvil 3404. Theplurality of sensors 3410 a, 3410 b may comprise any suitable sensorsfor detecting one or more parameters of the end effector 3400 and/or atissue section located between the body 3402 and the anvil 3404. Forexample, the plurality of sensors 3410 a, 3410 b may comprise magneticsensors, such as a Hall effect sensor, strain gauges, pressure sensors,inductive sensors, such as an eddy current sensor, resistive sensors,capacitive sensors, optical sensors, any combination thereof, and/or anyother suitable sensor.

In one embodiment, the plurality of sensors 3410 a, 3410 b comprise aplurality of pressure sensors positioned under the breakaway washer3408. Each of the sensors 3410 a, 3410 b is configured to detect apressure generated by the presence of compressed tissue between the body3402 and the anvil 3404. In some embodiments the plurality of sensors3410 a, 3410 b are configured to detect the impedance of a tissuesection located between the anvil 3404 and the body 3402. The detectedimpedance may be indicative of the thickness and/or fullness of tissuelocated between the anvil 3404 and the body 3402. The plurality ofsensors 3410 a, 3410 b generate a plurality of signals indicative of thedetected pressure. The plurality of generated signals is provided to aprocessor, such as, for example, the primary processor 2006. The primaryprocessor 2006 applies one or more algorithms and/or look-up tablesbased on the input from the plurality of sensors 3410 a, 3410 b todetermine one or more parameters of the end effector 3400 and/or atissue section located between the body 3402 and the anvil 3404. Forexample, in one embodiment comprising a plurality of pressure sensors,the processor 2006 is configured to apply an algorithm to quantitativelycompare the output of the plurality of sensors 3410 a, 3410 b withrespect to each other and with respect to a predetermined threshold. Inone embodiment, if the delta, or difference, between the outputs of theplurality of sensors 3410 a, 3410 b is greater than a predeterminedthreshold, feedback is provided to the operator indicating a potentialuneven loading condition. In some embodiments, the end effector 3400 maybe coupled to a shaft comprising one or more additional sensors, suchas, for example, the drive shaft 3504 described in connection to FIG. 50below.

FIGS. 48A-48D illustrate a clamping process of the circular stapler 3400illustrated in FIG. 47. FIG. 48A illustrates the circular stapler 3400in an initial position with the anvil 3404 and the body 3402 in a closedconfiguration. The circular stapler 3400 is positioned at a treatmentsite in the closed configuration. Once the circular stapler 3400 ispositioned, the anvil 3404 is moved distally to disengage with the body3402 and create a gap configured to receive a tissue section 3412therein, as illustrated in FIG. 48B. The tissue section 3412 iscompressed to a predetermined compression 3414 between the anvil 3404and the body 3402, as shown in FIG. 48C. The tissue section 3412 isfurther compressed between the anvil 3404 and the body 3402. Theadditional compression deploys one or more staples from the body 3402into the tissue section 3412. The staples are shaped by the anvil 3404.FIG. 48D illustrates the circular stapler 3400 in position correspondingto staple deployment. Proper staple deployment is dependent on obtaininga proper bite of tissue between the body 3402 and the anvil 3404. Theplurality of sensors 3410 a, 3410 b disposed on the anvil 3404 allow aprocessor to determine that a proper bite of tissue is located betweenthe anvil 3404 and the body 3402 prior to deployment of the staples.

FIG. 49 illustrates one embodiment of a circular staple anvil 3452 andan electrical connector 3466 configured to interface therewith. Theanvil 3452 comprises an anvil head 3454 coupled to an anvil shaft 3456.A breakaway washer 3458 is coupled to the anvil head 3452. A pluralityof pressure sensors 3460 a, 3460 b are coupled to the anvil head 3452between the anvil head 3452 and the breakaway washer 3458. A flexcircuit 3462 is formed on the shaft 3456. The flex circuit 3462 iscoupled to the plurality of pressure sensors 3460 a, 3460 b. One or morecontacts 3464 are formed on the shaft 3456 to couple the flex circuit3462 to one or more circuits, such as, for example, the control circuit2000 of the surgical instrument 10. The flex circuit 3462 may be coupledto the one or more circuits by an electrical connector 3466. Theelectrical connector 3466 is coupled to the anvil 3454. For example, inone embodiment, the shaft 3456 is hollow and configured to receive theelectrical connector 3466 therein. The electrical connector 3466comprises a plurality of contacts 3468 configured to interface with thecontacts 3464 formed on the anvil shaft 3456. The plurality of contacts3468 on the electrical connector 3466 are coupled to a flex circuit 3470which is coupled the one or more circuits, such as, for example, acontrol circuit 2000.

FIG. 50 illustrates one embodiment of a surgical instrument 3500comprising a sensor 3506 coupled to a drive shaft 3504 of the surgicalinstrument 3500. The surgical instrument 3500 may be similar to thesurgical instrument 10 described above. The surgical instrument 3500comprises a handle 3502 and a drive shaft 3504 coupled to a distal endof the handle. The drive shaft 3504 is configured to receive an endeffector (not shown) at the distal end. A sensor 3506 is fixedly mountedin the drive shaft 3504. The sensor 3506 is configured to detect one ormore parameters of the drive shaft 3504. The sensor 3506 may compriseany suitable sensor, such as, for example, a magnetic sensor, such as aHall effect sensor, a strain gauge, a pressure sensor, an inductivesensor, such as an eddy current sensor, a resistive sensor, a capacitivesensor, an optical sensor, and/or any other suitable sensor.

In some embodiments, the sensor 3506 comprises a magnetic Hall effectsensor. A magnet 3508 is located within the drive shaft 3504. The sensor3506 is configured to detect a magnetic field generated by the magnet3508. The magnet 3508 is coupled to a spring-backed bracket 3510. Thespring-backed bracket 3510 is coupled to the end effector. Thespring-backed bracket 3510 is moveable in response to an action of theend effector, for example, compression of an anvil towards a body and/orsecond jaw member. The spring-backed bracket 3510 moves the magnet 3508in response to the movement of the end effector. The sensor 3506 detectsthe change in the magnetic field generated by the magnet 3508 andgenerates a signal indicative of the movement of the magnet 3508. Themovement of the magnet 3508 may correspond to, for example, thethickness of tissue clamped by the end effector. The thickness of thetissue may be displayed to an operator by, for example, a display 3512embedded in the handle 3502 of the surgical instrument 3500. In someembodiments, the Hall effect sensor may be combined with one or moreadditional sensors, such as, for example, the pressure sensorsillustrated in FIG. 47.

FIG. 51 is a flow chart illustrating one embodiment of a process 3550for determining uneven tissue loading in an end effector, for example,the end effector 3400 illustrated in FIG. 47 coupled to the surgicalinstrument 3500 illustrated in FIG. 50. In one embodiment, the process3550 comprises utilizing one or more first sensors 3552, such as, forexample, a plurality of pressure sensors, to detect 3554 the presence oftissue within an end effector. During a clamping operation of the endeffector 3400, the input from the pressure sensors, P, is analyzed todetermine the value of P. If P is less 3556 than a predeterminedthreshold, the end effector 3400 continues 3558 the clamping operation.If P is greater than or equal to 3560 the predetermined threshold,clamping is stopped. The delta (difference) between the plurality ofsensors 3552 is compared 3562. If the delta is greater than apredetermined delta, the surgical instrument 3500 displays 3564 awarning to the user. The warning may comprise, for example, a messageindicating that there is uneven clamping in the end effector. If thedelta is less than or equal to the predetermined delta, the input of theone or more sensors 3552 is compared to an input from an additionalsensor 3566.

In some embodiments, a second sensor 3566 is configured to detect one ormore parameters of the surgical instrument 3500. For example, in onesome embodiments, a magnetic sensor, such as, for example, a Hall effectsensor, is located in a shaft 3504 of the surgical instrument 3500. Thesecond sensor 3566 generates a signal indicative of the one or moreparameters of the surgical instrument 3500. A preset calibration curveis applied 3568 to the input from the second sensor 3566. The presetcalibration curve may adjust 3568 a signal generated by the secondsensor 3566, such as, for example, a Hall voltage generated by a Halleffect sensor. For example, in one embodiment, the Hall effect voltageis adjusted such that the generated Hall effect voltage is set at apredetermined value when the gap between the anvil 3404 and the body3402, X1, is equal to zero. The adjusted sensor 3566 input is used tocalculate 3570 a distance, X3, between the anvil 3404 and the body 3402when the pressure threshold P is met. The clamping process is continued3572 to deploy a plurality of staples into the tissue section clamped inthe end effector 3400. The input from the second sensor 3566 changesdynamically during the clamping procedure and is used to calculate thedistance, X2, between the anvil 3404 and the body 3402 in real-time. Areal-time percent compression is calculated 3574 and displayed to anoperator. In one embodiment, the percent compression is calculated as:[(((X3−X2)/X3)*100].

In some embodiments, one or more of the sensors illustrated in FIGS.28-50 are used to indicate: whether the anvil is attached to the body ofthe surgical device; the compressed tissue gap; and/or whether the anvilis in a proper position for removing the device, or any combination ofthese indicators.

In some embodiments, one or more of the sensors illustrated in FIGS.28-50 are used to affect device performance. One or more controlparameters of a surgical device 10 may be adjusted by at least onesensor output. For example, in some embodiments, the speed control of afiring operation may be adjusted by the output of one or more sensors,such as, for example, a Hall effect sensor. In some embodiments, one ormore the sensors may adjust a closure and/or clamping operation based onload and/or tissue type. In some embodiments, multiple stage compressionsensors allow the surgical instrument 10 to stop closure at apredetermined load and/or a predetermined displacement. The controlcircuit 2000 may apply one or more predetermined algorithms to applyvarying compression to a tissue section to determine a tissue type, forexample, based on a tissue response. The algorithms may be varied basedon closure rate and/or predetermined tissue parameters. In someembodiments, one or more sensors are configured to detect a tissueproperty and one or more sensors are configured to detect a deviceproperty and/or configuration parameter. For example, in one embodiment,capacitive blocks may be formed integrally with a staple cartridge tomeasure skew.

Circuitry and Sensors For Powered Medical Device

FIG. 52 illustrates one embodiment of an end effector 3600 configured todetermine one or more parameters of a tissue section during a clampingoperation. The end effector 3600 comprises a first jaw member, or anvil,3602 pivotally coupled to a second jaw member 3604. The second jawmember 3604 is configured to receive a staple cartridge 3606 therein.The staple cartridge 3606 contains a plurality of staples (not shown)configured to be deployed into a tissue section during a clamping andstapling operation. The staple cartridge 3606 comprises a staplecartridge deck 3622 having a predetermined height. The staple cartridge3606 further comprises a slot 3624 defined within the body of the staplecartridge, similar to slot 193 described above. A Hall effect sensor3608 is configured to detect the distance 3616 between the Hall effectsensor 3608 and a magnet 3610 coupled to the second jaw member 3604. Thedistance 3616 between the Hall effect sensor 3608 and the magnet 3610 isindicative of a thickness of tissue located between the anvil 3602 andthe staple cartridge deck 3622.

The second jaw member 3604 is configured to receive a plurality ofstaple cartridge 3606 types. The types of staple cartridge 3606 may varyby, for example, containing different length staples, comprising abuttress material, and/or containing different types of staples. In someembodiments, the height 3618 of the staple cartridge deck 3622 may varybased on the type of staple cartridge 3606 coupled to the second jawmember 3604. The varying cartridge height 3618 may result in aninaccurate thickness measurement by the Hall effect sensor 3608. Forexample, in one embodiment, a first cartridge comprises a firstcartridge deck height X and a second cartridge comprises a secondcartridge deck height Y, where Y>X. A fixed Hall effect sensor 3608 andfixed magnet will produce an accurate thickness measurement only for oneof the two cartridge deck heights. In some embodiments, an adjustablemagnet is used to compensate for various deck heights.

In some embodiments, the second jaw member 3604 and the staple cartridge3606 comprise a magnet cavity 3614. The magnet cavity 3614 is configuredto receive the magnet 3610 therein. The magnet is coupled to aspring-arm 3612. The spring-arm 3612 is configured to bias the magnettowards the upper surface of the magnet cavity 3614. A depth 3620 of themagnet cavity 3614 varies depending on the deck height 3618 of thestaple cartridge 3606. For example, each staple cartridge 3606 maydefine a cavity depth 3620 such that the upper surface of the cavity3614 is a set distance from the plane of the deck 3622. The magnet 3610is biased against the upper surface of the cavity 3614. The magneticreference of the magnet 3610, as viewed by the Hall effect sensor 3608,is consistent relative to all cartridge decks but variable relative tothe slot 3624. For example, in some embodiments, the upper-biased magnet3610 and the cavity 3614 provide a set distance 3616 from the Halleffect sensor 3608 to the magnet 3610, regardless of the staplecartridge 3606 inserted into the second jaw member 3604. The setdistance 3616 allows the Hall effect sensor 3608 to generate an accuratethickness measurement irrespective of the staple cartridge 3606 type. Insome embodiments, the depth 3620 of the cavity 3614 may be adjusted tocalibrate the Hall effect sensor 3608 for one or more surgicalprocedures.

FIGS. 53A and 53B illustrate an embodiment of an end effector 3650configured to normalize a Hall effect voltage irrespective of a deckheight of a staple cartridge 3656. FIG. 53A illustrates one embodimentof the end effector 3650 comprising a first cartridge 3656 a insertedtherein. The end effector 3650 comprises a first jaw member, or anvil,3652 pivotally coupled to a second jaw member 3654 to grasp tissuetherebetween. The second jaw member 3654 is configured to receive astaple cartridge 3656 a. The staple cartridge 3656 a may comprise avariety of staple lengths, buttress materials, and/or deck heights. Amagnetic sensor 3658, such as, for example, a Hall effect sensor, iscoupled to the anvil 3652. The magnetic sensor 3658 is configured todetect a magnetic field generated by a magnet 3660. The detectedmagnetic field strength is indicative of the distance 3664 between themagnetic sensor 3658 and the magnet 3660, which may be indicative of,for example, a thickness of a tissue section grasped between the anvil3652 and the staple cartridge 3656. As noted above, various staplecartridges 3656 a may comprise varying deck heights which createdifferences in the calibrated compression gap 3664.

In some embodiments, a magnetic attenuator 3662 is coupled to the staplecartridge 3656 a. The magnetic attenuator 3662 is configured toattenuate the magnetic flux generated to by the magnet 3660. Themagnetic attenuator 3662 is calibrated to produce a magnetic flux basedon the height of the staple cartridge 3656 a. By attenuating the magnet3660 based on the staple cartridge 3656 type, the magnetic attenuator3662 normalizes the magnetic sensor 3658 signal to the same calibrationlevel for various deck heights. The magnetic attenuator 3662 maycomprise any suitable magnet attenuator, such as, for example, a ferrousmetallic cap. The magnetic attenuator 3662 is molded into the staplecartridge 3656 a such that the magnetic attenuator 3662 is positionedabove the magnet 3660 when the staple cartridge 3656 is inserted intothe second jaw member 3654.

In some embodiments, attenuation of the magnet 3660 is not required forthe deck height of the staple cartridge. FIG. 53B illustrates oneembodiment of the end effector 3650 comprising a second staple cartridge3656 b coupled to the second jaw member 3654. The second staplecartridge 3656 b comprises a deck height matching the calibration of themagnet 3660 and the Hall effect sensor 3658, and therefore does notrequire attenuation. As shown in FIG. 53B, the second staple cartridge3656 b comprises a cavity 3666 in place of the magnetic attenuator 3662of the first staple cartridge 3656 a. In some embodiments, larger and/orsmaller attenuation members are provided depending on the height of thecartridge deck. The design of the attenuation member 3662 shape may beoptimized to create features in the response signal generated by theHall effect sensor 3658 that allow for the distinction of one or moreadditional cartridge attributes.

FIG. 54 is a logic diagram illustrating one embodiment of a process 3670for determining when the compression of tissue within an end effector,such as, for example, the end effector 3650 illustrated in FIGS.53A-53B, has reached a steady state. In some embodiments, a clinicianinitiates 3672 a clamping procedure to clamp tissue within the endeffector, for example, between an anvil 3652 and staple cartridge 3656.The end effector engages 3674 with tissue during the clamping procedure.Once the tissue has been engaged 3674, the end effector begins 3676 realtime gap monitoring. The real time gap monitoring monitors the gapbetween, for example, the anvil 3652 and the staple cartridge 3656 ofthe end effector 3650. The gap may be monitored by, for example, asensor 3658, such as a Hall effect sensor, coupled to the end effector3650. The sensor 3658 may be coupled to a processor, such as, forexample, the primary processor 2006. The processor determines 3678 whentissue clamping requirements of the end effector 3650 and/or the staplecartridge 3656 have been met. Once the processor determines that thetissue has stabilized, the process indicates 3680 to the user that thetissue has stabilized. The indication may be provided by, for example, adisplay embedded within a surgical instrument 10.

In some embodiments, the gap measurement is provided by a Hall effectsensor. The Hall effect sensor may be located, for example, at thedistal tip of an anvil 3652. The Hall effect sensor is configured tomeasure the gap between the anvil 3652 and a staple cartridge 3656 deckat the distal tip. The measured gap may be used to calculate a jawclosure gap and/or to monitor a change in tissue compression of a tissuesection clamped in the end effector 3650. In one embodiment, the Halleffect sensor is coupled to a processor, such as, for example, theprimary processor 2006. The processor is configured to receive real timemeasurements from the Hall effect sensor and compare the received signalto a predetermined set of criteria. For example, in one embodiment, alogic equation at equally spaced intervals, such as one second, is usedto indicate stabilization of a tissue section to the user when a gapreading remains unchanged for a predetermined interval, such as, forexample, 3.0 seconds. Tissue stabilization may also be indicated after apredetermined time period, such as, for example, 15.0 seconds. Asanother example, tissue stabilization may be indicated whenyn=yn+1=yn+2, where y equals a gap measurement of the Hall effect sensorand n is a predetermined measurement interval. A surgical instrument 10may display an indication to a user, such as, for example, a graphicaland/or numerical representation, when stabilization has occurred.

FIG. 55 is a graph 3690 illustrating various Hall effect sensor readings3692 a-3692 d. As shown in graph 3690, a thickness, or compression, of atissue section stabilizes after a predetermined time period. Aprocessor, such as, for example, the primary processor 2006, may beconfigured to indicate when the calculated thickness from a sensor, suchas a Hall effect sensor, is relatively consistent or constant over apredetermined time period. The processor 2006 may indicate to a user,for example, through a number display, that the tissue has stabilized.

FIG. 56 is a logic diagram illustrating one embodiment of a process 3700for determining when the compression of tissue within an end effector,such as, for example, the end effector 3650 illustrated in FIGS.53A-53B, has reached a steady state. In some embodiments, a clinicianinitiates 3702 a clamping procedure to clamp tissue within the endeffector, for example, between an anvil 3652 and staple cartridge 3656.The end effector engages 3704 with tissue during the clamping procedure.Once the tissue has been engaged 3704, the end effector begins 3706 realtime gap monitoring. The real time gap monitoring technique monitors3706 the gap between, for example, the anvil 3652 and the staplecartridge 3656 of the end effector 3650. The gap may be monitored 3706by, for example, a sensor 3658, such as a Hall effect sensor, coupled tothe end effector 3650. The sensor 3658 may be coupled to a processor,such as, for example, the primary processor 2006. The processor isconfigured to execute one or more algorithms determine when tissuesection compressed by the end effector 3650 has stabilized.

For example, in the embodiment illustrated in FIG. 56, the process 3700is configured to utilize a slop calculation to determine stabilizationof tissue. The processor calculates 3708 the slope, S, of an input froma sensor, such as a Hall effect sensor. The slope may be calculated 3708by, for example, the equation S=((V_1−V_2))/((T_1−T_2)). The processorcompares 3710 the calculated slope to a predetermined value, such as,for example, 0.005 volts/sec. If the value of the calculated slope isgreater than the predetermined value, the processor resets 3712 a count,C, to zero. If the calculated slope is less than or equal to thepredetermined value, the processor increments 3714 the value of thecount C. The count, C, is compared 3716 to a predetermined thresholdvalue, such as, for example, 3. If the value of the count C is greaterthan or equal to the predetermined threshold value, the processorindicates 3718 to the user that the tissue section has stabilized. Ifthe value of the count C is less than the predetermined threshold value,the processor continues monitoring the sensor 3658. In variousembodiments, the slope of the sensor input, the change in the slope,and/or any other suitable change in the input signal may be monitored.

In some embodiments, an end effector, such as for example, the endeffectors 3600, 3650 illustrated in FIGS. 52, 53A, and 53B may comprisea cutting member deployable therein. The cutting member may comprise,for example, an I-Beam configured to simultaneously cut a tissue sectionlocated between an anvil 3602 and a staple cartridge 3608 and to deploystaples from the staple cartridge 3608. In some embodiments, the I-Beammay comprise only a cutting member and/or may only deploy one or morestaples. Tissue flow during firing may affect the proper formation ofstaples. For example, during I-Beam deployment, fluid in the tissue maycause the thickness of tissue to temporarily increase, causing improperdeployment of staples.

FIG. 57 is a logic diagram illustrating one embodiment of a process 3730for controlling an end effector to improve proper staple formationduring deployment. The control process 3730 comprises generating 3732 asensor measurement indicative of the thickness of a tissue sectionwithin the end effector 3650, such as for example, a Hall effect voltagegenerated by a Hall effect sensor. The sensor measurement is converted3734 to a digital signal by an analog-to-digital convertor. The digitalsignal is calibrated 3736. The calibration 3736 may be performed by, forexample, a processor and/or a dedicated calibration circuit. The digitalsignal is calibrated 3736 based on one or more calibration curve inputs.The calibrated digital signal is displayed 3738 to an operator by, forexample, a display 2026 embedded in a surgical instrument 10. Thecalibrated signal may be displayed 3738 as a thickness measurement of atissue section grasped between the anvil 3652 and the staple cartridge3656 and/or as a unit-less range.

In some embodiments, the generated 3732 Hall effect voltage is used tocontrol an I-beam. For example, in the illustrated embodiment, the Halleffect voltage is provided to a processor configured to controldeployment of an I-Beam within an end effector, such as, for example,the primary processor 2006. The processor receives the Hall effectvoltage and calculates the voltage rate of change over a predeterminedtime period. The processor compares 3740 the calculated rate of changeto a predetermined value, x1. If the calculated rate of change isgreater than the predetermined value, x1, the processor slows 3742 thespeed of the I-Beam. The speed may be reduced by, for example,decrementing a speed variable by a predetermined unit. If the calculatedvoltage rate of change is less than or equal to the predetermine value,x1, the processor maintains 3744 the current speed of the I-Beam.

In some embodiments, the processor may temporarily reduce the speed ofthe I-Beam to compensate, for example, for thicker tissue, unevenloading, and/or any other tissue characteristic. For example, in oneembodiment, the processor is configured to monitor 3740 the rate ofvoltage change of a Hall effect sensor. If the rate of change monitored3740 by the processor exceeds a first predetermine value, x1, theprocessor slows down or stops deployment of the I-Beam until the rate ofchange is less than a second predetermined value, x2. When the rate ofchange is less than the second predetermined value, x2, the processormay return the I-beam to normal speed. In some embodiments, the sensorinput may be generated by for example, a pressure sensor, a straingauge, a Hall effect sensor, and/or any other suitable sensor. In someembodiments, the processor may implement one or more pause points duringdeployment of an I-Beam. For example, in some embodiments, the processormay implement three predetermined pause points, at which the processorpauses deployment of the I-Beam for a predetermined time period. Thepause points are configured to provide optimized tissue flow control.

FIG. 58 is a logic diagram illustrating one embodiment of a process 3750for controlling an end effector to allow for fluid evacuation andprovide improved staple formation. The process 3750 comprises generating3752 a sensor measurement, such as, for example, a Hall effect voltage.The sensor measurement may be indicative of, for example, the thicknessof a tissue section grasped between an anvil 3652 and a staple cartridge3656 of an end effector 3650. The generated signal is provided to ananalog-to-digital convertor for conversion 3754 to a digital signal. Theconverted signal is calibrated 3756 based on one or more inputs, suchas, for example, a second sensor input and/or a predeterminedcalibration curve. The calibrated signal is representative of one ormore parameters of the end effector 3650, such as, for example, thethickness of a tissue section grasped therein. The calibrated thicknessmeasurement may be displayed to a user as a thickness and/or as aunit-less range. The calibrated thickness may be displayed by, forexample, a display 2026 embedded in a surgical instrument 10 coupled tothe end effector 3650.

In some embodiments, the calibrated thickness measurement is used tocontrol deployment of an I-Beam and/or other firing member within theend effector 3650. The calibrated thickness measurement is provided to aprocessor. The processor compares 3760 the change in the calibratedthickness measurement to a predetermined threshold percentage, x. If therate of change of the thickness measurement is greater than x, theprocessor slows 3762 the speed, or rate of deployment, of the I-Beamwithin the end effector. The processor may slow 3762 the speed of theI-Beam by, for example, decrementing a speed variable by a predeterminedunit. If the rate of change of the thickness measurement is less than orequal to x, the processor maintains 3764 the speed of the I-Beam withinthe end effector 3650. The real time feedback of tissue thickness and/orcompression allows the surgical instrument 10 to affect the firing speedto allow for fluid evacuation and/or provide improved staple form.

In some embodiments, the sensor reading generated 3752 by the sensor,for example, a Hall effect voltage, may be adjusted by one or moreadditional sensor inputs. For example, in one embodiment, a generated3752 Hall effect voltage may be adjusted by an input from a micro-straingauge sensor on the anvil 3652. The micro-strain gauge may be configuredto monitor the strain amplitude of the anvil 3652. The generated 3752Hall effect voltage may be adjusted by the monitored strain amplitude toindicate, for example, partial proximal or distal tissue bites. Timebased monitoring of the micro-strain and Hall effect sensor outputduring clamping allows one or more algorithms and/or look-up tables torecognize tissue characteristics and clamping positioning anddynamically adjust tissue thickness measurements to control firing speedof, for example, an I-Beam. In some embodiments, the processor mayimplement one or more pause points during deployment of an I-Beam. Forexample, in some embodiments, the processor may implement threepredetermined pause points, at which the processor pauses deployment ofthe I-Beam for a predetermined time period. The pause points areconfigured to provide optimized tissue flow control.

FIGS. 59A-59B illustrate one embodiment of an end effector 3800comprising a pressure sensor. The end effector 3800 comprises a firstjaw member, or anvil, 3802 pivotally coupled to a second jaw member3804. The second jaw member 3804 is configured to receive a staplecartridge 3806 therein. The staple cartridge 3806 comprises a pluralityof staples. A first sensor 3808 is coupled to the anvil 3802 at a distaltip. The first sensor 3808 is configured to detect one or moreparameters of the end effector, such as, for example, the distance, orgap 3814, between the anvil 3802 and the staple cartridge 3806. Thefirst sensor 3808 may comprise any suitable sensor, such as, forexample, a magnetic sensor. A magnet 3810 may be coupled to the secondjaw member 3804 and/or the staple cartridge 3806 to provide a magneticsignal to the magnetic sensor.

In some embodiments, the end effector 3800 comprises a second sensor3812. The second sensor 3812 is configured to detect one or moreparameters of the end effector 3800 and/or a tissue section locatedtherebetween. The second sensor 3812 may comprise any suitable sensor,such as, for example, one or more pressure sensors. The second sensor3812 may be coupled to the anvil 3802, the second jaw member 3804,and/or the staple cartridge 3806. A signal from the second sensor 3812may be used to adjust the measurement of the first sensor 3808 to adjustthe reading of the first sensor to accurately represent proximal and/ordistal positioned partial bites true compressed tissue thickness. Insome embodiments, the second sensor 3812 may be surrogate with respectto the first sensor 3808.

In some embodiments, the second sensor 3812 may comprise, for example, asingle continuous pressure sensing film and/or an array of pressuresensing films. The second sensor 3812 is coupled to the deck of thestaple cartridge 3806 along the central axis covering, for example, aslot 3816 configured to receive a cutting and/or staple deploymentmember. The second sensor 3812 provides signals indicate of theamplitude of pressure applied by the tissue during a clamping procedure.During firing of the cutting and/or deployment member, the signal fromthe second sensor 3812 may be severed, for example, by cuttingelectrical connections between the second sensor 3812 and one or morecircuits. In some embodiments, a severed circuit of the second sensor3812 may be indicative of a spent staple cartridge 3806. In otherembodiments, the second sensor 3812 may be positioned such thatdeployment of a cutting and/or deployment member does not sever theconnection to the second sensor 3812.

FIG. 60 illustrates one embodiment of an end effector 3850 comprising asecond sensor 3862 located between a staple cartridge 3806 and a secondjaw member 3804. The end effector 3850 comprises a first jaw member, oranvil, 3852 pivotally coupled to a second jaw member 3854. The secondjaw member 3854 is configured to receive a staple cartridge 3856therein. A first sensor 3858 is coupled to the anvil 3852 at a distaltip. The first sensor 3858 is configured to detect one or moreparameters of the end effector 3850, such as, for example, the distance,or gap 3864, between the anvil 3852 and the staple cartridge 3856. Thefirst sensor 3858 may comprise any suitable sensor, such as, forexample, a magnetic sensor. A magnet 3860 may be coupled to the secondjaw member 3854 and/or the staple cartridge 3856 to provide a magneticsignal to the magnetic sensor. In some embodiments, the end effector3850 comprises a second sensor 3862 similar in all respect to the secondsensor 3812 of FIGS. 59A-59B, except that it is located between thestaple cartridge 3856 and the second jaw member 3864.

FIG. 61 is a logic diagram illustrating one embodiment of a process 3870for determining and displaying the thickness of a tissue section clampedin an end effector 3800 or 3850, according to FIGS. 59A-59B or FIG. 60.The process comprises obtaining a Hall effect voltage 3872, for example,through a Hall effect sensor located at the distal tip of the anvil3802. The Hall effect voltage 3872 is proved to an analog to digitalconverter 3874 and converted into a digital signal, the digital signalis provided to a process, such as for example the primary processor2006. The primary processor 2006 calibrates 3874 the curve input of theHall effect voltage 3872 signal. Pressure sensors, such as for examplesecond sensor 3812, is configured to measure 3880 one or more parametersof, for example, the end effector 3800, such as for example the amountof pressure being exerted by the anvil 3802 on the tissue clamped in theend effector 3800. In some embodiments the pressure sensors may comprisea single continuous pressure sensing film and/or array of pressuresensing films. The pressure sensors may thus be operable determinevariations in the measure pressure at different locations between theproximal and distal ends of the end effector 3800. The measured pressureis provided to the processor, such as for example the primary processor2006. The primary processor 2006 uses one or more algorithms and/orlookup tables to adjust 3882 the Hall effect voltage 3872 in response tothe pressure measured by the pressure sensors 3880 to more accuratelyreflect the thickness of the tissue clamped between, for example, theanvil 3802 and the staple cartridge 3806. The adjusted thickness isdisplayed 3878 to an operator by, for example, a display 2026 embeddedin the surgical instrument 10.

FIG. 62 illustrates one embodiment of an end effector 3900 comprising aplurality of second sensors 3192 a-3192 b located between a staplecartridge 3906 and an elongated channel 3916. The end effector 3900comprises a first jaw member or anvil 3902 pivotally coupled to a secondjaw member or elongated channel 3904. The elongated channel 3904 isconfigured to receive a staple cartridge 3906 therein. The anvil 3902further comprises a first sensor 3908 located in the distal tip. Thefirst sensor 3908 is configured to detect one or more parameters of theend effector 3900, such as, for example, the distance, or gap, betweenthe anvil 3902 and the staple cartridge 3906. The first sensor 3908 maycomprise any suitable sensor, such as, for example, a magnetic sensor. Amagnet 3910 may be coupled to the elongated channel 3904 and/or thestaple cartridge 3906 to provide a magnetic signal to the first sensor3908. In some embodiments, the end effector 3900 comprises a pluralityof second sensors 3912 a-3912 c located between the staple cartridge3906 and the elongated channel 3904. The second sensors 3912 a-3912 cmay comprise any suitable sensors, such as for instance piezo-resistivepressure film strips. In some embodiments, the second sensors 3912a-3912 c may be uniformly distributed between the distal and proximalends of the end effector 3900.

In some embodiments, signals from the second sensors 3912 a-3912 c maybe used to adjust the measurement of the first sensor 3908. Forinstance, the signals from the second sensors 3912 a-3912 c may be usedto adjust the reading of the first sensor 3908 to accurately representthe gap between the anvil 3908 and the staple cartridge 3906, which mayvary between the distal and proximal ends of the end effector 3900,depending on the location and/or density of tissue 3920 between theanvil 3902 and the staple cartridge 3906. FIG. 11 illustrates an exampleof a partial bite of tissue 3920. As illustrated for purposes of thisexample, the tissue is located only in the proximal area of the endeffector 3900, creating a high pressure 3918 area near the proximal areaof the end effector 3900 and a corresponding low pressure 3916 area nearthe distal end of the end effector.

FIGS. 63A and 63B further illustrate the effect of a full versus partialbite of tissue 3920. FIG. 63A illustrates the end effector 3900 with afull bite of tissue 3920, where the tissue 3920 is of uniform density.With a full bite of tissue 3920 of uniform density, the measured firstgap 3914 a at the distal tip of the end effector 3900 may beapproximately the same as the measured second gap 3922 a in the middleor proximal end of the end effector 3900. For example, the first gap3914 a may measure 2.4 mm, and the second gap may measure 2.3 mm. FIG.63B illustrates an end effector 3900 with a partial bite of tissue 3920,or alternatively a full bit of tissue 3920 of non-uniform density. Inthis case, the first gap 3914 b will measure less than the second gap3922 b measured at the thickest or densest portion of the tissue 3920.For example, the first gap may measure 1.0 mm, while the second gap maymeasure 1.9 mm. In the conditions illustrated in FIGS. 63A and 63B,signals from the second sensors 3912 a-3912 c, such as for instancemeasured pressure at different points along the length of the endeffector 3900, may be employed by the instrument to determine tissue3920 placement and/or material properties of the tissue 3920. Theinstrument may further be operable to use measured pressure over time torecognize tissue characteristics and tissue position, and dynamicallyadjust tissue thickness measurements.

FIG. 64 illustrates one embodiment of an end effector 3950 comprising acoil 3958 and oscillator circuit 3962 for measuring the gap between theanvil and the staple cartridge 3956. The end effector 3950 comprises afirst jaw member or anvil 3952 pivotally coupled to a second jaw memberor elongated channel 3954. The elongated channel 3954 is configured toreceive a staple cartridge 3956 therein. In some embodiments the staplecartridge 3954 further comprises a coil 3958 and an oscillator circuit3962 located at the distal end. The coil 3958 and oscillator circuit3962 are operable as eddy current sensors and/or inductive sensors. Thecoil 3958 and oscillator circuit 3962 can detect eddy currents and/orinduction as a target 3960, such as for instance the distal tip of theanvil 3952, approaches the coil 3958. The eddy current and/or inductiondetected by the coil 3958 and oscillator circuit 3962 can be used todetect the distance or gap between the anvil 3952 and staple cartridge3956.

FIG. 65 illustrates and alternate view of the end effector 3950. Asillustrated, in some embodiments external wiring 3964 may supply powerto the oscillator circuit 3962. The external wiring 3964 may be placedalong the outside of the elongated channel 3954.

FIG. 66 illustrates examples of the operation of a coil 3958 to detecteddy currents 3972 in a target 3960. Alternating current flowing throughthe coil 3958 at a chose frequency generates a magnetic field 3970around the coil 3958. When the coil 3958 is at is position 3976 a acertain distance away from the target 3960, the coil 3958 will notinduce an eddy current 3972. When the coil 3958 is at a position 3976 bclose to an electrically conductive target 3960 and eddy current 3972 isproduced in the target 3960. When the coil 3958 is at a position 3976 cnear a flaw in the target 3960, the flaw may disrupt the eddy currentcirculation; in this case, the magnetic coupling with the coil 3958 ischanged and a defect signal 3974 can be read by measuring the coilimpedance variation.

FIG. 67 illustrates a graph 3980 of a measured quality factor 3984, themeasured inductance 3986, and measure resistance 3988 of the radius of acoil 3958 as a function of the coil's 3958 standoff 3978 to a target3960. The quality factor 3984 depends on the standoff 3978, while boththe inductance 3986 and resistance 3988 are functions of displacement. Ahigher quality factor 3984 results in a more purely reactive sensor. Thespecific value of the inductance 3986 is constrained only by the needfor a manufacturable coil 3958 and a practical circuit design that burnsa reasonable amount of energy at a reasonable frequency. Resistance 3988is a parasitic effect.

The graph 3980 illustrates how inductance 3986, resistance 3988, and thequality factor 3984 depend on the target standoff 3978. As the standoff3978 increases, the inductance 3986 increases by a factor of four, theresistance 3988 decreases slightly and as a consequence the qualityfactor 3984 increases. The change in all three parameters is highlynonlinear and each curve tends to decay roughly exponentially asstandoff 3978 increases. The rapid loss of sensitivity with distancestrictly limits the range of an eddy current sensor to approximately ½the coil diameter.

FIG. 68 illustrates one embodiment of an end effector 4000 comprising anemitter and sensor 4008 placed between the staple cartridge 4006 and theelongated channel 4004. The end effector 4000 comprises a first jawmember or anvil 4002 pivotally coupled to a second jaw member orelongated channel 4004. The elongated channel 3904 is configured toreceive a staple cartridge 4006 therein. In some embodiments, the endeffector 4000 further comprises an emitter and sensor 4008 locatedbetween the staple cartridge 4006 and the elongated channel 4004. Theemitter and sensor 4008 can be any suitable device, such as for instancea MEMS ultrasonic transducer. In some embodiments, the emitter andsensor may be placed along the length of the end effector 4000.

FIG. 69 illustrates an embodiment of an emitter and sensor 4008 inoperation. The emitter and sensor 4008 may be operable to emit a pulse4014 and sense the reflected signal 4016 of the pulse 4014. The emitterand sensor 4008 may further be operable to measure the time of flight4018 between the issuance of the pulse 4014 and the reception of thereflected signal 4016. The measured time of flight 4018 can be used todetermine the thickness of tissue compressed in the end effector 4000along the entire length of the end effector 4000. In some embodiments,the emitter and sensor 4008 may be coupled to a processor, such as forinstance the primary processor 2006. The processor 2006 may be operableto use the time of flight 4018 to determine additional information aboutthe tissue, such as for instance whether the tissue was diseased,bunched, or damaged. The surgical instrument can further be operable toconvey this information to the operator of the instrument.

FIG. 70 illustrates the surface of an embodiment of an emitter andsensor 4008 comprising a MEMS transducer.

FIG. 71 illustrates a graph 4020 of an example of the reflected signal4016 that may be measured by the emitter and sensor 4008 of FIG. 69.FIG. 71 illustrates the amplitude 4022 of the reflected signal 4016 as afunction of time 4024. As illustrated, the amplitude of the transmittedpulse 4026 is greater than the amplitude of the reflected pulses 4028a-4028 c. The amplitude of the transmitted pulse 4026 may be of a knownor expected value. The first reflected pulse 4028 a may be, for example,from the tissue enclosed by the end effector 4000. The second reflectedpulse 4028 b may be, for example, from the lower surface of the anvil4002. The third reflected pulse 4028 c may be, for example, from theupper surface of the anvil 4002.

FIG. 72 illustrates an embodiment of an end effector 4050 that isconfigured to determine the location of a cutting member or knife 4058.The end effector 4050 comprises a first jaw member or anvil 4052pivotally coupled to a second jaw member or elongated channel 4054. Theelongated channel 4054 is configured to receive a staple cartridge 4056therein. The staple cartridge 4056 further comprises a slot 4058 (notshown) and a cutting member or knife 4062 located therein. The knife4062 is operably coupled to a knife bar 4064. The knife bar 4064 isoperable to move the knife 4062 from the proximal end of the slot 4058to the distal end. The end effector 4050 may further comprise an opticalsensor 4060 located near the proximal end of the slot 4058. The opticalsensor may be coupled to a processor, such as for instance the primaryprocessor 2006. The optical sensor 4060 may be operable to emit anoptical signal towards the knife bar 4064. The knife bar 4064 mayfurther comprise a code strip 4066 along its length. The code strip 4066may comprise cut-outs, notches, reflective pieces, or any otherconfiguration that is optically readable. The code strip 4066 is placedsuch that the optical signal from the optical sensor 4060 will reflectoff or through the code strip 4066. As the knife 4062 and knife bar 4064move 4068 along the slot 4058, the optical sensor 4060 will detect thereflection of the emitted optical signal coupled to the code strip 4066.The optical sensor 4060 may be operable to communicate the detectedsignal to the processor 2006. The processor 2006 may be configured touse the detected signal to determine the position of the knife 4062. Theposition of the knife 4062 may be sensed more precisely by designing thecode strip 4066 such that the detected optical signal has a gradual riseand fall.

FIG. 73 illustrates an example of the code strip 4066 in operation withred LEDs 4070 and infrared LEDs 4072. For purposes of this example only,the code strip 4066 comprises cut-outs. As the code strip 4066 moves4068, the light emitted by the red LEDs 4070 will be interrupted as thecut-outs passed before it. The infrared LEDs 4072 will therefore detectthe motion 4068 of the code strip 4066, and therefore, by extension, themotion of the knife 4062.

Monitoring Device Degradation Based on Component Evaluation

FIG. 74 depicts a partial view of the end effector 300 of the surgicalinstrument 10. In the example form depicted in FIG. 74, the end effector300 comprises a staple cartridge 1100 which is similar in many respectsto the staple cartridge 304 (FIG. 20). Several parts of the end effector300 are omitted to enable a clearer understanding of the presentdisclosure. In certain instances, the end effector 300 may include afirst jaw such as, for example, the anvil 306 (FIG. 20) and a second jawsuch as, for example, the channel 198 (FIG. 20). In certain instances,as described above, the channel 198 may accommodate a staple cartridgesuch as, for example, the staple cartridge 304 or the staple cartridge1100, for example. At least one of the channel 198 and the anvil 306 maybe movable relative to the other one of the channel 198 and the anvil306 to capture tissue between the staple cartridge 1100 and the anvil306. Various actuation assemblies are described herein to facilitationmotion of the channel 198 and/or the anvil 306 between an openconfiguration (FIG. 1) and a closed configuration (FIG. 75), for example

In certain instances, as described above, the E-beam 178 can be advanceddistally to deploy the staples 191 into the captured tissue and/oradvance the cutting edge 182 between a plurality of positions to engageand cut the captured tissue. As illustrated in FIG. 74, the cutting edge182 can be advanced distally along a path defined by the slot 193, forexample. In certain instances, the cutting edge 182 can be advanced froma proximal portion 1102 of the staple cartridge 1100 to a distal portion1104 of the staple cartridge 1100 to cut the captured tissue, asillustrated in FIG. 74. In certain instances, the cutting edge 182 canbe retracted proximally from the distal portion 1104 to the proximalportion 1102 by retraction of the E-beam 178 proximally, for example.

In certain instances, the cutting edge 182 can be employed to cut tissuecaptured by the end effector 300 in multiple procedures. The reader willappreciate that repetitive use of the cutting edge 182 may affect thesharpness of the cutting edge 182. The reader will also appreciate thatas the sharpness of the cutting edge 182 decreases, the force requiredto cut the captured tissue with the cutting edge 182 may increase.Referring to FIGS. 74-76, in certain instances, the surgical instrument10 may comprise a module 1106 (FIG. 76) for monitoring the sharpness ofthe cutting edge 182 during, before, and/or after operation of thesurgical instrument 10 in a surgical procedure, for example. In certaininstances, the module 1106 can be employed to test the sharpness of thecutting edge 182 prior to utilizing the cutting edge 182 to cut thecaptured tissue. In certain instances, the module 1106 can be employedto test the sharpness of the cutting edge 182 after the cutting edge 182has been used to cut the captured tissue. In certain instances, themodule 1106 can be employed to test the sharpness of the cutting edge182 prior to and after the cutting edge 182 is used to cut the capturedtissue. In certain instances, the module 1106 can be employed to testthe sharpness of the cutting edge 182 at the proximal portion 1102and/or at the distal portion 1104.

Referring to FIGS. 74-76, the module 1106 may include one or moresensors such as, for example, an optical sensor 1108; the optical sensor1108 of the module 1106 can be employed to test the reflective abilityof the cutting edge 182, for example. In certain instances, the abilityof the cutting edge 182 to reflect light may correlate with thesharpness of the cutting edge 182. In other words, a decrease in thesharpness of the cutting edge 182 may result in a decrease in theability of the cutting edge 182 to reflect the light. Accordingly, incertain instances, the dullness of the cutting edge 182 can be evaluatedby monitoring the intensity of the light reflected from the cutting edge182, for example. In certain instances, the optical sensor 1108 maydefine a light sensing region. The optical sensor 1108 can be orientedsuch that the optical sensing region is disposed in the path of thecutting edge 182, for example. The optical sensor 1108 may be employedto sense the light reflected from the cutting edge 182 while the cuttingedge 182 is in the optical sensing region, for example. A decrease inintensity of the reflected light beyond a threshold can indicate thatthe sharpness of the cutting edge 182 has decreased beyond an acceptablelevel.

Referring again to FIGS. 74-76, the module 1106 may include one or morelights sources such as, for example, a light source 1110. In certaininstances, the module 1106 may include a microcontroller 1112(“controller”) which may be operably coupled to the optical sensor 1108,as illustrated in FIG. 76. In certain instances, the controller 1112 mayinclude a microprocessor 1114 (“processor”) and one or more computerreadable mediums or memory units 1116 (“memory”). In certain instances,the memory 1116 may store various program instructions, which whenexecuted may cause the processor 1114 to perform a plurality offunctions and/or calculations described herein. In certain instances,the memory 1116 may be coupled to the processor 1114, for example. Apower source 1118 can be configured to supply power to the controller1112, the optical sensors 1108, and/or the light sources 1110, forexample. In certain instances, the power source 1118 may comprise abattery (or “battery pack” or “power pack”), such as a Li ion battery,for example. In certain instances, the battery pack may be configured tobe releasably mounted to the handle 14 for supplying power to thesurgical instrument 10. A number of battery cells connected in seriesmay be used as the power source 4428. In certain instances, the powersource 1118 may be replaceable and/or rechargeable, for example.

The controller 1112 and/or other controllers of the present disclosuremay be implemented using integrated and/or discrete hardware elements,software elements, and/or a combination of both. Examples of integratedhardware elements may include processors, microprocessors,microcontrollers, integrated circuits, ASICs, PLDs, DSPs, FPGAs, logicgates, registers, semiconductor devices, chips, microchips, chip sets,microcontrollers, SoC, and/or SIP. Examples of discrete hardwareelements may include circuits and/or circuit elements such as logicgates, field effect transistors, bipolar transistors, resistors,capacitors, inductors, and/or relays. In certain instances, thecontroller 1112 may include a hybrid circuit comprising discrete andintegrated circuit elements or components on one or more substrates, forexample.

In certain instances, the controller 1112 and/or other controllers ofthe present disclosure may be an LM 4F230H5QR, available from TexasInstruments, for example. In certain instances, the Texas InstrumentsLM4F230H5QR is an ARM Cortex-M4F Processor Core comprising on-chipmemory of 256 KB single-cycle flash memory, or other non-volatilememory, up to 40 MHz, a prefetch buffer to improve performance above 40MHz, a 32 KB single-cycle SRAM, internal ROM loaded with StellarisWare®software, 2 KB EEPROM, one or more PWM modules, one or more QEI analog,one or more 12-bit ADC with 12 analog input channels, among otherfeatures that are readily available. Other microcontrollers may bereadily substituted for use with the present disclosure. Accordingly,the present disclosure should not be limited in this context.

In certain instances, the light source 1110 can be employed to emitlight which can be directed at the cutting edge 182 in the opticalsensing region, for example. The optical sensor 1108 may be employed tomeasure the intensity of the light reflected from the cutting edge 182while in the optical sensing region in response to exposure to the lightemitted by the light source 1110. In certain instances, the processor1114 may receive one or more values of the measured intensity of thereflected light and may store the one or more values of the measuredintensity of the reflected light on the memory 1116, for example. Thestored values can be detected and/or recorded before, after, and/orduring a plurality of surgical procedures performed by the surgicalinstrument 10, for example.

In certain instances, the processor 1114 may compare the measuredintensity of the reflected light to a predefined threshold values thatmay be stored on the memory 1116, for example. In certain instances, thecontroller 1112 may conclude that the sharpness of the cutting edge 182has dropped below an acceptable level if the measured light intensityexceeds the predefined threshold value by 1%, 5%, 10%, 25%, 50%, 100%and/or more than 100%, for example. In certain instances, the processor1114 can be employed to detect a decreasing trend in the stored valuesof the measured intensity of the light reflected from the cutting edge182 while in the optical sensing region.

In certain instances, the surgical instrument 10 may include one or morefeedback systems such as, for example, the feedback system 1120. Incertain instances, the processor 1114 can employ the feedback system1120 to alert a user if the measured light intensity of the lightreflected from cutting edge 182 while in the optical sensing region isbeyond the stored threshold value, for example. In certain instances,the feedback system 1120 may comprise one or more visual feedbacksystems such as display screens, backlights, and/or LEDs, for example.In certain instances, the feedback system 1120 may comprise one or moreaudio feedback systems such as speakers and/or buzzers, for example. Incertain instances, the feedback system 1120 may comprise one or morehaptic feedback systems, for example. In certain instances, the feedbacksystem 1120 may comprise combinations of visual, audio, and/or tactilefeedback systems, for example.

In certain instances, the surgical instrument 10 may comprise a firinglockout mechanism 1122 which can be employed to prevent advancement ofthe cutting edge 182. Various suitable firing lockout mechanisms aredescribed in greater detail in U.S. Patent Publication No. 2014/0001231,entitled FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS,and filed Jun. 28, 2012, which is hereby incorporated by referenceherein in its entirety. In certain instances, as illustrated in FIG. 76,the processor 1114 can be operably coupled to the lockout mechanism1122; the processor 1114 may employ the lockout mechanism 1122 toprevent advancement of the cutting edge 182 in the event it isdetermined that the measured intensity of the light reflected from thecutting edge 182 is beyond the stored threshold, for example. In otherwords, the processor 1114 may activate the lockout mechanism 1122 if thecutting edge is not sufficiently sharp to cut the tissue captured by theend effector 300.

In certain instances, the optical sensor 1108 and the light source 1110can be housed at a distal portion of the shaft assembly 200. In certaininstances, the sharpness of cutting edge 182 can be evaluated by theoptical sensor 1108, as described above, prior to transitioning thecutting edge 182 into the end effector 300. The firing bar 172 (FIG. 20)may advance the cutting edge 182 through the optical sensing regiondefined by the optical sensor 1108 while the cutting edge 182 is in theshaft assembly 182 and prior to entering the end effector 300, forexample. In certain instances, the sharpness of cutting edge 182 can beevaluated by the optical sensor 1108 after retracting the cutting edge182 proximally from the end effector 300. The firing bar 172 (FIG. 20)may retract the cutting edge 182 through the optical sensing regiondefined by the optical sensor 1108 after retracting the cutting edge 182from the end effector 300 into the shaft assembly 200, for example.

In certain instances, the optical sensor 1108 and the light source 1110can be housed at a proximal portion of the end effector 300 which can beproximal to the staple cartridge 1100, for example. The sharpness ofcutting edge 182 can be evaluated by the optical sensor 1108 aftertransitioning the cutting edge 182 into the end effector 300 but priorto engaging the staple cartridge 1100, for example. In certaininstances, the firing bar 172 (FIG. 20) may advance the cutting edge 182through the optical sensing region defined by the optical sensor 1108while the cutting edge 182 is in the end effector 300 but prior toengaging the staple cartridge 1100, for example.

In various instances, the sharpness of cutting edge 182 can be evaluatedby the optical sensor 1108 as the cutting edge 182 is advanced by thefiring bar 172 through the slot 193. As illustrated in FIG. 74, theoptical sensor 1108 and the light source 1110 can be housed at theproximal portion 1102 of the staple cartridge 1100, for example; and thesharpness of cutting edge 182 can be evaluated by the optical sensor1108 at the proximal portion 1102, for example. The firing bar 172 (FIG.20) may advance the cutting edge 182 through the optical sensing regiondefined by the optical sensor 1108 at the proximal portion 1102 beforethe cutting edge 182 engages tissue captured between the staplecartridge 1100 and the anvil 306, for example. In certain instances, asillustrated in FIG. 74, the optical sensor 1108 and the light source1110 can be housed at the distal portion 1104 of the staple cartridge1100, for example. The sharpness of cutting edge 182 can be evaluated bythe optical sensor 1108 at the distal portion 1104. In certaininstances, the firing bar 172 (FIG. 20) may advance the cutting edge 182through the optical sensing region defined by the optical sensor 1108 atthe distal portion 1104 after the cutting edge 182 has passed throughthe tissue captured between the staple cartridge 1100 and the anvil 306,for example.

Referring again to FIG. 74, the staple cartridge 1100 may comprise aplurality of optical sensors 1108 and a plurality of corresponding lightsources 1110, for example. In certain instances, a pair of the opticalsensor 1108 and the light source 1110 can be housed at the proximalportion 1102 of the staple cartridge 1100, for example; and a pair ofthe optical sensor 1108 and the light source 1110 can be housed at thedistal portion 1104 of the staple cartridge 1100, for example. In suchinstances, the sharpness of the cutting edge 182 can be evaluated afirst time at the proximal portion 1102 prior to engaging the tissue,for example, and a second time at the distal portion 1104 after passingthrough the captured tissue, for example.

The reader will appreciate that an optical sensor 1108 may evaluate thesharpness of the cutting edge 182 a plurality of times during a surgicalprocedure. For example, the sharpness of the cutting edge can beevaluated a first time during advancement of the cutting edge 182through the slot 193 in a firing stroke, and a second time duringretraction of the cutting edge 182 through the slot 193 in a returnstroke, for example. In other words, the light reflected from thecutting edge 182 can be measured by the same optical sensor 1108 once asthe cutting edge is advanced through the optical sensing region, andonce as the cutting edge 182 is retracted through the optical sensingregion, for example.

The reader will appreciate that the processor 1114 may receive aplurality of readings of the intensity of the light reflected from thecutting edge 182 from one or more of the optical sensors 1108. Incertain instances, the processor 1114 may be configured to discardoutliers and calculate an average reading from the plurality ofreadings, for example. In certain instances, the average reading can becompared to a threshold stored in the memory 1116, for example. Incertain instances, the processor 1114 may be configured to alert a userthrough the feedback system 1120 and/or activate the lockout mechanism1122 if it is determined that the calculated average reading is beyondthe threshold stored in the memory 1116, for example.

In certain instances, as illustrated in FIGS. 75, 77, and 78, a pair ofthe optical sensor 1108 and the light source 1110 can be positioned onopposite sides of the staple cartridge 1100. In other words, the opticalsensor 1108 can be positioned on a first side 1124 of the slot 193, forexample, and the light source 1110 can be positioned on a second side1126, opposite the first side 1124, of the slot 193, for example. Incertain instances, the pair of the optical sensor 1108 and the lightsource 1110 can be substantially disposed in a plane transecting thestaple cartridge 1100, as illustrated in FIG. 75. The pair of theoptical sensor 1108 and the light source 1110 can be oriented to definean optical sensing region that is positioned, or at least substantiallypositioned, on the plane transecting the staple cartridge 1100, forexample. Alternatively, the pair of the optical sensor 1108 and thelight source 1110 can be oriented to define an optical sensing regionthat is positioned proximal to the plane transecting the staplecartridge 1100, for example, as illustrated in FIG. 78.

In certain instances, a pair of the optical sensor 1108 and the lightsource 1110 can be positioned on a same side of the staple cartridge1100. In other words, as illustrated in FIG. 79, the pair of the opticalsensor 1108 and the light source 1110 can be positioned on a first sideof the cutting edge 182, e.g. the side 1128, as the cutting edge 182 isadvanced through the slot 193. In such instances, the light source 1110can be oriented to direct light at the side 1128 of the cutting edge182; and the intensity of the light reflected from the side 1128, asmeasured by the optical sensor 1108, may represent the sharpness of theside 1128.

In certain instances, as illustrated in FIG. 80, a second pair of theoptical sensor 1108 and the light source 1110 can be positioned on asecond side of the cutting edge 182, e.g. the side 1130, for example.The second pair can be employed to evaluate the sharpness of the side1130. For example, the light source 1110 of the second pair can beoriented to direct light at the side 1130 of the cutting edge 182; andthe intensity of the light reflected from the side 1130, as measured bythe optical sensor 1108 of the second pair, may represent the sharpnessof the side 1130. In certain instances, the processor can be configuredto assess the sharpness of the cutting edge 182 based upon the measuredintensities of the light reflected from the sides 1128 and 1130 of thecutting edge 182, for example.

In certain instances, as illustrated in FIG. 75, a pair of the opticalsensor 1108 and the light source 1110 can be housed at the distalportion 1104 of the staple cartridge 1100. As illustrated in FIG. 81,the light source 1108 can be positioned, or at least substantiallypositioned, on an axis LL which extends longitudinally along the path ofthe cutting edge 182 through the slot 193, for example. In addition, thelight source 1110 can be positioned distal to the cutting edge 182 andoriented to direct light at the cutting edge 182 as the cutting edge isadvanced toward the light source 1110, for example. Furthermore, theoptical sensor 1108 can be positioned, or at least substantiallypositioned, along an axis AA that intersects the axis LL, as illustratedin FIG. 81. In certain instances, the axis AA may be perpendicular tothe axis LL, for example. In any event, the optical sensor 1108 can beoriented to define an optical sensing region at the intersection of theaxis LL and the axis AA, for example.

The reader will appreciate that the position, orientation and/or numberof optical sensors and corresponding light sources described herein inconnection with the surgical instrument 10 are example embodimentsintended for illustration purposes. Various other arrangements ofoptical sensors and light sources can be employed by the presentdisclosure to evaluate the sharpness of the cutting edge 182.

The reader will appreciate that advancement of the cutting edge 182through the tissue captured by the end effector 300 may cause thecutting edge to collect tissue debris and/or bodily fluids during eachfiring of the surgical instrument 10. Such debris may interfere with theability of the module 1106 to accurately evaluate the sharpness of thecutting edge 182. In certain instances, the surgical instrument 10 canbe equipped with one or more cleaning mechanisms which can be employedto clean the cutting edge 182 prior to evaluating the sharpness of thecutting edge 182, for example. In certain instances, as illustrated inFIG. 82, a cleaning mechanism 1131 may comprise one or more cleaningmembers 1132, for example. In certain instances, the cleaning members1132 can be disposed on opposite sides of the slot 193 to receive thecutting edge 182 therebetween (See FIG. 82) as the cutting edge 182 isadvanced through the slot 193, for example. In certain instances, asillustrated in FIG. 82, the cleaning members 1132 may comprise wiperblades, for example. In certain instances, as illustrated in FIG. 83,the cleaning members 1132 may comprise sponges, for example. The readerwill appreciate that various other cleaning members can be employed toclean the cutting edge 182, for example.

Referring to FIG. 74, in certain instances, the staple cartridge 1100may include a first pair of the optical sensor 1108 and the light source1110, which can be housed in the proximal portion 1102 of the staplecartridge 1100, for example. Furthermore, as illustrated in FIG. 74, thestaple cartridge 1100 may include a first pair of the cleaning members1132, which can be housed in the proximal portion 1102 on opposite sidesof the slot 193. The first pair of the cleaning members 1132 can bepositioned distal to the first pair of the optical sensor 1108 and thelight source 1110, for example. As illustrated in FIG. 74, the staplecartridge 1100 may include a second pair of the optical sensor 1108 andthe light source 1110, which can be housed in the distal portion 1104 ofthe staple cartridge 1100, for example. As illustrated in FIG. 74, thestaple cartridge 1100 may include a second pair of the cleaning members1132, which can be housed in the distal portion 1104 on opposite sidesof the slot 193. The second pair of the cleaning members 1132 can bepositioned proximal to the second pair of the optical sensor 1108 andthe light source 1110.

Further to the above, as illustrated in FIG. 74, the cutting edge 182may be advanced distally in a firing stroke to cut tissue captured bythe end effector 300. As the cutting edge is advanced, a firstevaluation of the sharpness of the cutting edge 182 can be performed bythe first pair of the optical sensor 1108 and the light source 1110prior to tissue engagement by the cutting edge 182, for example. Asecond evaluation of the sharpness of the cutting edge 182 can beperformed by the second pair of the optical sensor 1108 and the lightsource 1110 after the cutting edge 182 has transected the capturedtissue, for example. The cutting edge 182 may be advanced through thesecond pair of the cleaning members 1132 prior to the second evaluationof the sharpness of the cutting edge 182 to remove any debris collectedby the cutting edge 182 during the transection of the captured tissue.

Further to the above, as illustrated in FIG. 74, the cutting edge 182may be retracted proximally in a return stroke. As the cutting edge isretracted, a third evaluation of the sharpness of the cutting edge 182can be performed by the first pair of the optical sensor 1108 and thelight source 1110 during the return stroke. The cutting edge 182 may beretracted through the first pair of the cleaning members 1132 prior tothe third evaluation of the sharpness of the cutting edge 182 to removeany debris collected by the cutting edge 182 during the transection ofthe captured tissue, for example.

In certain instances, one or more of the lights sources 1110 maycomprise one or more optical fiber cables. In certain instances, one ormore flex circuits 1134 can be employed to transmit energy from thepower source 1118 to the optical sensors 1108 and/or the light sources1110. In certain instances, the flex circuits 1134 may be configured totransmit one or more of the readings of the optical sensors 1108 to thecontroller 1112, for example.

Referring now to FIG. 84, a staple cartridge 4300 is depicted; thestaple cartridge 4300 is similar in many respects to the staplecartridge 304 (FIG. 20). For example, the staple cartridge 4300 can beemployed with the end effector 300. In certain instances, as illustratedin FIG. 84, the staple cartridge 4300 may comprise a sharpness testingmember 4302 which can be employed to test the sharpness of the cuttingedge 182. In certain instances, the sharpness testing member 4302 can beattached to and/or integrated with the cartridge body 194 of the staplecartridge 4300, for example. In certain instances, the sharpness testingmember 4302 can be disposed in the proximal portion 1102 of the staplecartridge 4300, for example. In certain instances, as illustrated inFIG. 84, the sharpness testing member 4302 can be disposed onto acartridge deck 4304 of the staple cartridge 4300, for example.

In certain instances, as illustrated in FIG. 84, the sharpness testingmember 4302 can extend across the slot 193 of the staple cartridge 4300to bridge, or at least partially bridge, the gap defined by the slot193, for example. In certain instances, the sharpness testing member4302 may interrupt, or at least partially interrupt, the path of thecutting edge 182. The cutting edge 182 may engage, cut, and/or passthrough the sharpness testing member 4302 as the cutting edge 182 isadvanced during a firing stroke, for example. In certain instances, thecutting edge 182 may be configured to engage, cut, and/or pass throughthe sharpness testing member 4302 prior to engaging tissue captured bythe end effector 300 in a firing stroke, for example. In certaininstances, the cutting edge 182 may be configured to engage thesharpness testing member 4302 at a proximal end 4306 of the sharpnesstesting member 4302, and exit and/or disengage the sharpness testingmember 4302 at a distal end 4308 of the sharpness testing member 4302,for example. In certain instances, the cutting edge 182 can traveland/or cut through the sharpness testing member 4302 a distance (D)between the proximal end 4306 and the distal end 4308, for example, asthe cutting edge 182 is advanced during a firing stroke.

Referring primarily to FIGS. 84 and 85, the surgical instrument 10 maycomprise a sharpness testing module 4310 for testing the sharpness ofthe cutting edge 182, for example. In certain instances, the module 4310can evaluate the sharpness of the cutting edge 182 by testing theability of the cutting edge 182 to be advanced through the sharpnesstesting member 4302. For example, the module 4310 can be configured toobserve the time period the cutting edge 182 takes to fully transectand/or completely pass through at least a predetermined portion of thesharpness testing member 4302. If the observed time period exceeds apredetermined threshold, the module 4310 may conclude that the sharpnessof the cutting edge 182 has dropped below an acceptable level, forexample.

In certain instances, the module 4310 may include a microcontroller 4312(“controller”) which may include a microprocessor 4314 (“processor”) andone or more computer readable mediums or memory units 4316 (“memory”).In certain instances, the memory 4316 may store various programinstructions, which when executed may cause the processor 4314 toperform a plurality of functions and/or calculations described herein.In certain instances, the memory 4316 may be coupled to the processor4314, for example. A power source 4318 can be configured to supply powerto the controller 4312, for example. In certain instances, the powersource 4138 may comprise a battery (or “battery pack” or “power pack”),such as a Li ion battery, for example. In certain instances, the batterypack may be configured to be releasably mounted to the handle 14. Anumber of battery cells connected in series may be used as the powersource 4318. In certain instances, the power source 4318 may bereplaceable and/or rechargeable, for example.

In certain instances, the processor 4313 can be operably coupled to thefeedback system 1120 and/or the lockout mechanism 1122, for example.

Referring to FIGS. 84 and 85, the module 4310 may comprise one or moreposition sensors. Example position sensors and positioning systemssuitable for use with the present disclosure are described in U.S.patent application Ser. No. 13/803,210, entitled SENSOR ARRANGEMENTS FORABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS, and filed Mar. 14,2013, the disclosure of which is hereby incorporated by reference hereinin its entirety. In certain instances, the module 4310 may include afirst position sensor 4320 and a second position sensor 4322. In certaininstances, the first position sensor 4320 can be employed to detect afirst position of the cutting edge 182 at the proximal end 4306 of thesharpness testing member 4302, for example; and the second positionsensor 4322 can be employed to detect a second position of the cuttingedge 182 at the distal end 4308 of the sharpness cutting member 4302,for example.

In certain instances, the position sensors 4320 and 4322 can be employedto provide first and second position signals, respectively, to themicrocontroller 4312. It will be appreciated that the position signalsmay be analog signals or digital values based on the interface betweenthe microcontroller 4312 and the position sensors 4320 and 4322. In oneembodiment, the interface between the microcontroller 4312 and theposition sensors 4320 and 4322 can be a standard serial peripheralinterface (SPI), and the position signals can be digital valuesrepresenting the first and second positions of the cutting edge 182, asdescribed above.

Further to the above, the processor 4314 may determine the time periodbetween receiving the first position signal and receiving the secondposition signal. The determined time period may correspond to the timeit takes the cutting edge 182 to advance through the sharpness testingmember 4302 from the first position at the proximal end 4306 of thesharpness testing member 4302, for example, to the second position atthe distal end 4308 of the sharpness testing member 4302, for example.In at least one example, the controller 4312 may include a time elementwhich can be activated by the processor 4314 upon receipt of the firstposition signal, and deactivated upon receipt of the second positionsignal. The time period between the activation and deactivation of thetime element may correspond to the time it takes the cutting edge 182 toadvance from the first position to the second position, for example. Thetime element may comprise a real time clock, a processor configured toimplement a time function, or any other suitable timing circuit.

In various instances, the controller 4312 can compare the time period ittakes the cutting edge 182 to advance from the first position to thesecond position to a predefined threshold value to assess whether thesharpness of the cutting edge 182 has dropped below an acceptable level,for example. In certain instances, the controller 4312 may conclude thatthe sharpness of the cutting edge 182 has dropped below an acceptablelevel if the measured time period exceeds the predefined threshold valueby 1%, 5%, 10%, 25%, 50%, 100% and/or more than 100%, for example.

Referring to FIG. 86, in various instances, an electric motor 4330 candrive the firing bar 172 (FIG. 20) to advance the cutting edge 182during a firing stroke and/or to retract the cutting edge 182 during areturn stroke, for example. A motor driver 4332 can control the electricmotor 4330; and a microcontroller such as, for example, themicrocontroller 4312 can be in signal communication with the motordriver 4332. As the electric motor 4330 advances the cutting edge 182,the microcontroller 4312 can determine the current drawn by the electricmotor 4330, for example. In such instances, the force required toadvance the cutting edge 182 can correspond to the current drawn by theelectric motor 4330, for example. Referring still to FIG. 86, themicrocontroller 4312 of the surgical instrument 10 can determine if thecurrent drawn by the electric motor 4330 increases during advancement ofthe cutting edge 182 and, if so, can calculate the percentage increaseof the current.

In certain instances, the current drawn by the electric motor 4330 mayincrease significantly while the cutting edge 182 is in contact with thesharpness testing member 4302 due to the resistance of the sharpnesstesting member 4302 to the cutting edge 182. For example, the currentdrawn by the electric motor 4330 may increase significantly as thecutting edge 182 engages, passes and/or cuts through the sharpnesstesting member 4302. The reader will appreciate that the resistance ofthe sharpness testing member 4302 to the cutting edge 182 depends, inpart, on the sharpness of the cutting edge 182; and as the sharpness ofthe cutting edge 182 decreases from repetitive use, the resistance ofthe sharpness testing member 4302 to the cutting edge 182 will increase.Accordingly, the value of the percentage increase of the current drawnby the motor 4330 while the cutting edge is in contact with thesharpness testing member 4302 can increase as the sharpness of thecutting edge 182 decreases from repetitive use, for example.

In certain instances, the determined value of the percentage increase ofthe current drawn by the motor 4330 can be the maximum detectedpercentage increase of the current drawn by the motor 4330. In variousinstances, the microcontroller 4312 can compare the determined value ofthe percentage increase of the current drawn by the motor 4330 to apredefined threshold value of the percentage increase of the currentdrawn by the motor 4330. If the determined value exceeds the predefinedthreshold value, the microcontroller 4312 may conclude that thesharpness of the cutting edge 182 has dropped below an acceptable level,for example.

In certain instances, as illustrated in FIG. 86, the processor 4314 canbe in communication with the feedback system 1120 and/or the lockoutmechanism 1122, for example. In certain instances, the processor 4314can employ the feedback system 1120 to alert a user if the determinedvalue of the percentage increase of the current drawn by the motor 4330exceeds the predefined threshold value, for example. In certaininstances, the processor 4314 may employ the lockout mechanism 1122 toprevent advancement of the cutting edge 182 if the determined value ofthe percentage increase of the current drawn by the motor 4330 exceedsthe predefined threshold value, for example.

In various instances, the microcontroller 43312 can utilize an algorithmto determine the change in current drawn by the electric motor 4330. Forexample, a current sensor can detect the current drawn by the electricmotor 4330 during the firing stroke. The current sensor can continuallydetect the current drawn by the electric motor and/or can intermittentlydetect the current draw by the electric motor. In various instances, thealgorithm can compare the most recent current reading to the immediatelyproceeding current reading, for example. Additionally or alternatively,the algorithm can compare a sample reading within a time period X to aprevious current reading. For example, the algorithm can compare thesample reading to a previous sample reading within a previous timeperiod X, such as the immediately proceeding time period X, for example.In other instances, the algorithm can calculate the trending average ofcurrent drawn by the motor. The algorithm can calculate the averagecurrent draw during a time period X that includes the most recentcurrent reading, for example, and can compare that average current drawto the average current draw during an immediately proceeding time periodtime X, for example.

Referring to FIG. 87, a method is depicted for evaluating the sharpnessof the cutting edge 182 of the surgical instrument 10; and variousresponses are outlined in the event the sharpness of the cutting edge182 drops to and/or below an alert threshold and/or a high severitythreshold, for example. In various instances, a microcontroller such as,for example, the microcontroller 4312 can be configured to implement themethod depicted in FIG. 87. In certain instances, the surgicalinstrument 10 may include a load cell 4334 (FIG. 86); as illustrated inFIG. 86, the microcontroller 4312 may be in communication with the loadcell 4334. In certain instances, the load cell 4334 may include a forcesensor such as, for example, a strain gauge, which can be operablycoupled to the firing bar 172, for example. In certain instances, themicrocontroller 4312 may employ the load cell 4334 to monitor the force(Fx) applied to the cutting edge 182 as the cutting edge 182 is advancedduring a firing stroke.

In certain instances, as illustrated in FIG. 88, the load cell 4334 canbe configured to monitor the force (Fx) applied to the cutting edge 182while the cutting edge 182 is engaged and/or in contact with thesharpness testing member 4302, for example. The reader will appreciatethat the force (Fx) applied by the sharpness testing member 4302 to thecutting edge 182 while the cutting edge 182 is engaged and/or in contactwith the sharpness testing member 4302 may depend, at least in part, onthe sharpness of the cutting edge 182. In certain instances, a decreasein the sharpness of the cutting edge 182 can result in an increase inthe force (FX) required for the cutting edge 182 to cut or pass throughthe sharpness testing member 4302. For example, as illustrated in FIG.88, graphs 4336, 4338, and 4340 represent the force (Fx) applied to thecutting edge 182 while the cutting edge 182 travels a predefineddistance (D) through three identical, or at least substantiallyidentical, sharpness testing members 4302. The graph 4336 corresponds toa first sharpness of the cutting edge 182; the graph 4338 corresponds toa second sharpness of the cutting edge 182; and the graph 4340corresponds to a third sharpness of the cutting edge 182. The firstsharpness is greater than the second sharpness, and the second sharpnessis greater than the third sharpness.

In certain instances, the microcontroller 4312 may compare a maximumvalue of the monitored force (Fx) applied to the cutting edge 182 to oneor more predefined threshold values. In certain instances, asillustrated in FIG. 88, the predefined threshold values may include analert threshold (F1) and/or a high severity threshold (F2). In certaininstances, as illustrated in the graph 4336 of FIG. 88, the monitoredforce (Fx) can be less than the alert threshold (F1), for example. Insuch instances, as illustrated in FIG. 87, the sharpness of the cuttingedge 182 is at a good level and the microcontroller 4312 may take noaction to alert a user as to the status of the cutting edge 182 or mayinform the user that the sharpness of the cutting edge 182 is within anacceptable range.

In certain instances, as illustrated in the graph 4338 of FIG. 88, themonitored force (Fx) can be more than the alert threshold (F1) but lessthan the high severity threshold (F2), for example. In such instances,as illustrated in FIG. 87, the sharpness of the cutting edge 182 can bedulling but still within an acceptable level. The microcontroller 4312may take no action to alert a user as to the status of the cutting edge182. Alternatively, the microcontroller 4312 may inform the user thatthe sharpness of the cutting edge 182 is within an acceptable range.Alternatively or additionally, the microcontroller 4312 may determine orestimate the number of cutting cycles remaining in the lifecycle of thecutting edge 182 and may alert the user accordingly.

In certain instances, the memory 4316 may include a database or a tablethat correlates the number of cutting cycles remaining in the lifecycleof the cutting edge 182 to predetermined values of the monitored force(Fx). The processor 4314 may access the memory 4316 to determine thenumber of cutting cycles remaining in the lifecycle of the cutting edge182 which correspond to a particular measured value of the monitoredforce (Fx) and may alert the user to the number of cutting cyclesremaining in the lifecycle of the cutting edge 182, for example.

In certain instances, as illustrated in the graph 4340 of FIG. 88, themonitored force (Fx) can be more than the high severity threshold (F2),for example. In such instances, as illustrated in FIG. 87, the sharpnessof the cutting edge 182 can be below an acceptable level In response,the microcontroller 4312 may employ the feedback system 1120 to warn theuser that the cutting edge 182 is too dull for safe use, for example. Incertain instances, the microcontroller 4312 may employ the lockoutmechanism 1122 to prevent advancement of the cutting edge 182 upondetection that the monitored force (Fx) exceeds the high severitythreshold (F2), for example. In certain instances, the microcontroller4312 may employ the feedback system 1120 to provide instructions to theuser for overriding the lockout mechanism 1122, for example.

Referring to FIG. 89, a method is depicted for determining whether acutting edge such as, for example, the cutting edge 182 is sufficientlysharp to be employed in transecting a tissue of a particular tissuethickness that is captured by the end effector 300, for example. Incertain instances, the microcontroller 4312 can be implemented toperform the method depicted in FIG. 16, for example. As described above,repetitive use of the cutting edge 182 may dull or reduce the sharpnessof the cutting edge 182 which may increase the force required for thecutting edge 182 to transect the captured tissue. In other words, thesharpness level of the cutting edge 182 can be defined by the forcerequired for the cutting edge 182 to transect the captured tissue, forexample. The reader will appreciate that the force required for thecutting edge 182 to transect a captured tissue may also depend on thethickness of the captured tissue. In certain instances, the greater thethickness of the captured tissue, the greater the force required for thecutting edge 182 to transect the captured tissue at the same sharpnesslevel, for example.

In certain instances, the cutting edge 182 may be sufficiently sharp fortransecting a captured tissue comprising a first thickness but may notbe sufficiently sharp for transecting a captured tissue comprising asecond thickness greater than the first thickness, for example. Incertain instances, a sharpness level of the cutting edge 182, as definedby the force required for the cutting edge 182 to transect a capturedtissue, may be adequate for transecting the captured tissue if thecaptured tissue comprises a tissue thickness that is in a particularrange of tissue thicknesses, for example. In certain instances, asillustrated in FIG. 90, the memory 4316 can store one or more predefinedranges of tissue thicknesses of tissue captured by the end effector 300;and predefined threshold forces associated with the predefined ranges oftissue thicknesses. In certain instances, each predefined thresholdforce may represent a minimum sharpness level of the cutting edge 182that is suitable for transecting a captured tissue comprising a tissuethickness (Tx) encompassed by the range of tissue thicknesses that isassociated with the predefined threshold force. In certain instances, ifthe force (Fx) required for the cutting edge 182 to transect thecaptured tissue, comprising the tissue thickness (Tx), exceeds thepredefined threshold force associated with the predefined range oftissue thicknesses that encompasses the tissue thickness (Tx), thecutting edge 182 may not be sufficiently sharp to transect the capturedtissue, for example.

In certain instances, the predefined threshold forces and theircorresponding predefined ranges of tissue thicknesses can be stored in adatabase and/or a table on the memory 4316 such as, for example, a table4342, as illustrated in FIG. 90. In certain instances, the processor4314 can be configured to receive a measured value of the force (Fx)required for the cutting edge 182 to transect a captured tissue and ameasured value of the tissue thickness (Tx) of the captured tissue. Theprocessor 4314 may access the table 4342 to determine the predefinedrange of tissue thicknesses that encompasses the measured tissuethickness (Tx). In addition, the processor 4314 may compare the measuredforce (Fx) to the predefined threshold force associated with thepredefined range of tissue thicknesses that encompasses the tissuethickness (Tx). In certain instances, if the measured force (Fx) exceedsthe predefined threshold force, the processor 4314 may conclude that thecutting edge 182 may not be sufficiently sharp to transect the capturedtissue, for example.

Further to the above, the processor 4314 may employ one or more tissuethickness sensing modules such as, for example, a tissue thicknesssensing module 4336 to determine the thickness of the captured tissue.Various suitable tissue thickness sensing modules are described in thepresent disclosure. In addition, various tissue thickness sensingdevices and methods, which are suitable for use with the presentdisclosure, are disclosed in U.S. Publication No. US 2011/0155781,entitled SURGICAL CUTTING INSTRUMENT THAT ANALYZES TISSUE THICKNESS, andfiled Dec. 24, 2009, the entire disclosure of which is herebyincorporated by reference herein.

In certain instances, the processor 4314 may employ the load cell 4334to measure the force (Fx) required for the cutting edge 182 to transecta captured tissue comprising a tissue thickness (Tx). The reader willappreciate that that the force applied to the cutting edge 182 by thecaptured tissue, while the cutting edge 182 is engaged and/or in contactwith the captured tissue, may increase as the cutting edge 182 isadvanced against the captured tissue up to the force (Fx) at which thecutting edge 182 may transect the captured tissue. In certain instances,the processor 4314 may employ the load cell 4334 to continually monitorthe force applied by the captured tissue against the cutting edge 182 asthe cutting edge 182 is advanced against the captured tissue. Theprocessor 4314 may continually compare the monitored force to thepredefined threshold force associated with the predefined tissuethickness range encompassing the tissue thickness (Tx) of the capturedtissue. In certain instances, if the monitored force exceeds thepredefined threshold force, the processor 4314 may conclude that thecutting edge is not sufficiently sharp to safely transect the capturedtissue, for example.

The method described in FIG. 89 outline various example actions that canbe taken by the processor 4313 in the event it is determined that thecutting edge 182 is not be sufficiently sharp to safely transect thecaptured tissue, for example. In certain instances, the microcontroller4312 may warn the user that the cutting edge 182 is too dull for safeuse, for example, through the feedback system 1120, for example. Incertain instances, the microcontroller 4312 may employ the lockoutmechanism 1122 to prevent advancement of the cutting edge 182 uponconcluding that the cutting edge 182 is not sufficiently sharp to safelytransect the captured tissue, for example. In certain instances, themicrocontroller 4312 may employ the feedback system 1120 to provideinstructions to the user for overriding the lockout mechanism 1122, forexample.

Multiple Motor Control For Powered Medical Device

FIGS. 91-93 illustrate various embodiments of an apparatus, system, andmethod for employing a common control module with a plurality of motorsin connection with a surgical instrument such as, for example, asurgical instrument 4400. The surgical instrument 4400 is similar inmany respects to other surgical instruments described by the presentdisclosure such as, for example, the surgical instrument 10 of FIG. 1which is described in greater detail above. For example, as illustratedin FIG. 91, the surgical instrument 4400 includes the housing 12, thehandle 14, the closure trigger 32, the shaft assembly 200, and thesurgical end effector 300. Accordingly, for conciseness and clarity ofdisclosure, a detailed description of certain features of the surgicalinstrument 4400, which are common with the surgical instrument 10, willnot be repeated here.

Referring primarily to FIG. 92, the surgical instrument 4400 may includea plurality of motors which can be activated to perform variousfunctions in connection with the operation of the surgical instrument4400. In certain instances, a first motor can be activated to perform afirst function; a second motor can be activated to perform a secondfunction; and a third motor can be activated to perform a thirdfunction. In certain instances, the plurality of motors of the surgicalinstrument 4400 can be individually activated to cause articulation,closure, and/or firing motions in the end effector 300. Thearticulation, closure, and/or firing motions can be transmitted to theend effector 300 through the shaft assembly 200, for example.

In certain instances, as illustrated in FIG. 92, the surgical instrument4400 may include a firing motor 4402. The firing motor 4402 may beoperably coupled to a firing drive assembly 4404 which can be configuredto transmit firing motions generated by the motor 4402 to the endeffector 300. In certain instances, the firing motions generated by themotor 4402 may cause the staples 191 to be deployed from the staplecartridge 304 into tissue captured by the end effector 300 and/or thecutting edge 182 to be advanced to cut the captured tissue, for example.

In certain instances, as illustrated in FIG. 92, the surgical instrument4400 may include an articulation motor 4406, for example. The motor 4406may be operably coupled to an articulation drive assembly 4408 which canbe configured to transmit articulation motions generated by the motor4406 to the end effector 300. In certain instances, the articulationmotions may cause the end effector 300 to articulate relative to theshaft assembly 200, for example. In certain instances, the surgicalinstrument 4400 may include a closure motor, for example. The closuremotor may be operably coupled to a closure drive assembly which can beconfigured to transmit closure motions to the end effector 300. Incertain instances, the closure motions may cause the end effector 300 totransition from an open configuration to an approximated configurationto capture tissue, for example. The reader will appreciate that themotors described herein and their corresponding drive assemblies areintended as examples of the types of motors and/or driving assembliesthat can be employed in connection with the present disclosure. Thesurgical instrument 4400 may include various other motors which can beutilized to perform various other functions in connection with theoperation of the surgical instrument 4400.

As described above, the surgical instrument 4400 may include a pluralityof motors which may be configured to perform various independentfunctions. In certain instances, the plurality of motors of the surgicalinstrument 4400 can be individually or separately activated to performone or more functions while the other motors remain inactive. Forexample, the articulation motor 4406 can be activated to cause the endeffector 300 to be articulated while the firing motor 4402 remainsinactive. Alternatively, the firing motor 4402 can be activated to firethe plurality of staples 191 and/or advance the cutting edge 182 whilethe articulation motor 4406 remains inactive.

In certain instances, the surgical instrument 4400 may include a commoncontrol module 4410 which can be employed with a plurality of motors ofthe surgical instrument 4400.

In certain instances, the common control module 4410 may accommodate oneof the plurality of motors at a time. For example, the common controlmodule 4410 can be separably couplable to the plurality of motors of thesurgical instrument 4400 individually. In certain instances, a pluralityof the motors of the surgical instrument 4400 may share one or morecommon control modules such as the module 4410. In certain instances, aplurality of motors of the surgical instrument 4400 can be individuallyand selectively engaged the common control module 4410. In certaininstances, the module 4410 can be selectively switched from interfacingwith one of a plurality of motors of the surgical instrument 4400 tointerfacing with another one of the plurality of motors of the surgicalinstrument 4400.

In at least one example, the module 4410 can be selectively switchedbetween operable engagement with the articulation motor 4406 andoperable engagement with the firing motor 4402. In at least one example,as illustrated in FIG. 92, a switch 4414 can be moved or transitionedbetween a plurality of positions and/or states such as a first position4416 and a second position 4418, for example. In the first position4416, the switch 4414 may electrically couple the module 4410 to thearticulation motor 4406; and in the second position 4418, the switch4414 may electrically couple the module 4410 to the firing motor 4402,for example. In certain instances, the module 4410 can be electricallycoupled to the articulation motor 4406, while the switch 4414 is in thefirst position 4416, to control the operation of the motor 4406 toarticulate the end effector 300 to a desired position. In certaininstances, the module 4410 can be electrically coupled to the firingmotor 4402, while the switch 4414 is in the second position 4418, tocontrol the operation of the motor 4402 to fire the plurality of staples191 and/or advance the cutting edge 182, for example. In certaininstances, the switch 4414 may be a mechanical switch, anelectromechanical switch, a solid state switch, or any suitableswitching mechanism.

Referring now to FIG. 93, an outer casing of the handle 14 of thesurgical instrument 4400 is removed and several features and elements ofthe surgical instrument 4400 are also removed for clarity of disclosure.In certain instances, as illustrated in FIG. 93, the surgical instrument4400 may include an interface 4412 which can be selectively transitionedbetween a plurality of positions and/or states. In a first positionand/or state, the interface 4412 may couple the module 4410 to a firstmotor such as, for example, the articulation motor 4406; and in a secondposition and/or state, the interface 4412 may couple the module 4410 toa second motor such as, for example, the firing motor 4402. Additionalpositions and/or states of the interface 4412 are contemplated by thepresent disclosure.

In certain instances, the interface 4412 is movable between a firstposition and a second position, wherein the module 4410 is coupled to afirst motor in the first position and a second motor in the secondposition. In certain instances, the module 4410 is decoupled from firstmotor as the interface 4412 is moved from the first position; and themodule 4410 is decoupled from second motor as the interface 4412 ismoved from the second position. In certain instances, a switch or atrigger can be configured to transition the interface 4412 between theplurality of positions and/or states. In certain instances, a triggercan be movable to simultaneously effectuate the end effector andtransition the control module 4410 from operable engagement with one ofthe motors of the surgical instrument 4400 to operable engagement withanother one of the motors of the surgical instrument 4400.

In at least one example, as illustrated in FIG. 93, the closure trigger32 can be operably coupled to the interface 4412 and can be configuredto transition the interface 4412 between a plurality of positions and/orstates. As illustrated in FIG. 93, the closure trigger 32 can bemovable, for example during a closure stroke, to transition theinterface 4412 from a first position and/or state to a second positionand/or state while transitioning the end effector 300 to an approximatedconfiguration to capture tissue by the end effector, for example.

In certain instances, in the first position and/or state, the module4410 can be electrically coupled to a first motor such as, for example,the articulation motor 4406, and in the second position and/or state,the module 4410 can be electrically coupled to a second motor such as,for example, the firing motor 4402. In the first position and/or state,the module 4410 may be engaged with the articulation motor 4406 to allowthe user to articulate the end effector 300 to a desired position; andthe module 4410 may remain engaged with the articulation motor 4406until the trigger 32 is actuated. As the user actuates the closuretrigger 32 to capture tissue by the end effector 300 at the desiredposition, the interface 4412 can be transitioned or shifted totransition the module 4410 from operable engagement with thearticulation motor 4406, for example, to operable engagement with thefiring motor 4402, for example. Once operable engagement with the firingmotor 4402 is established, the module 4410 may take control of thefiring motor 4402; and the module 4410 may activate the motor 4402, inresponse to user input, to fire the plurality of staples 191 and/oradvance the cutting edge 182, for example.

In certain instances, as illustrated in FIG. 93, the module 4410 mayinclude a plurality of electrical and/or mechanical contacts 4411adapted for coupling engagement with the interface 4412. The pluralityof motors of the surgical instrument 4400, which share the module 4410,may each comprise one or more corresponding electrical and/or mechanicalcontacts 4413 adapted for coupling engagement with the interface 4412,for example.

In various instances, the motors of the surgical instrument 4400 can beelectrical motors. In certain instances, one or more of the motors ofthe surgical instrument 4400 can be a DC brushed driving motor having amaximum rotation of, approximately, 25,000 RPM, for example. In otherarrangements, the motors of the surgical instrument 4400 may include oneor more motors selected from a group of motors comprising a brushlessmotor, a cordless motor, a synchronous motor, a stepper motor, or anyother suitable electric motor.

In various instances, as illustrated in FIG. 92, the common controlmodule 4410 may comprise a motor driver 4426 which may comprise one ormore H-Bridge field-effect transistors (FETs). The motor driver 4426 maymodulate the power transmitted from a power source 4428 to a motorcoupled to the module 4410 based on input from a microcontroller 4420(“controller”), for example. In certain instances, the controller 4420can be employed to determine the current drawn by the motor, forexample, while the motor is coupled to the module 4410, as describedabove.

In certain instances, the controller 4420 may include a microprocessor4422 (“processor”) and one or more computer readable mediums or memoryunits 4424 (“memory”). In certain instances, the memory 4424 may storevarious program instructions, which when executed may cause theprocessor 4422 to perform a plurality of functions and/or calculationsdescribed herein. In certain instances, one or more of the memory units4424 may be coupled to the processor 4422, for example.

In certain instances, the power source 4428 can be employed to supplypower to the controller 4420, for example. In certain instances, thepower source 4428 may comprise a battery (or “battery pack” or “powerpack”), such as a Li ion battery, for example. In certain instances, thebattery pack may be configured to be releasably mounted to the handle 14for supplying power to the surgical instrument 4400. A number of batterycells connected in series may be used as the power source 4428. Incertain instances, the power source 4428 may be replaceable and/orrechargeable, for example.

In various instances, the processor 4422 may control the motor driver4426 to control the position, direction of rotation, and/or velocity ofa motor that is coupled to the module 4410. In certain instances, theprocessor 4422 can signal the motor driver 4426 to stop and/or disable amotor that is coupled to the module 4410. It should be understood thatthe term processor as used herein includes any suitable microprocessor,microcontroller, or other basic computing device that incorporates thefunctions of a computer's central processing unit (CPU) on an integratedcircuit or at most a few integrated circuits. The processor is amultipurpose, programmable device that accepts digital data as input,processes it according to instructions stored in its memory, andprovides results as output. It is an example of sequential digitallogic, as it has internal memory. Processors operate on numbers andsymbols represented in the binary numeral system.

In one instance, the processor 4422 may be any single core or multicoreprocessor such as those known under the trade name ARM Cortex by TexasInstruments. In certain instances, the microcontroller 4420 may be an LM4F230H5QR, available from Texas Instruments, for example. In at leastone example, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4FProcessor Core comprising on-chip memory of 256 KB single-cycle flashmemory, or other non-volatile memory, up to 40 MHz, a prefetch buffer toimprove performance above 40 MHz, a 32 KB single-cycle SRAM, internalROM loaded with StellarisWare® software, 2 KB EEPROM, one or more PWMmodules, one or more QEI analog, one or more 12-bit ADC with 12 analoginput channels, among other features that are readily available for theproduct datasheet. Other microcontrollers may be readily substituted foruse with the module 4410. Accordingly, the present disclosure should notbe limited in this context.

In certain instances, the memory 4424 may include program instructionsfor controlling each of the motors of the surgical instrument 4400 thatare couplable to the module 4410. For example, the memory 4424 mayinclude program instructions for controlling the articulation motor4406. Such program instructions may cause the processor 4422 to controlthe articulation motor 4406 to articulate the end effector 300 inaccordance with user input while the articulation motor 4406 is coupledto the module 4410. In another example, the memory 4424 may includeprogram instructions for controlling the firing motor 4402. Such programinstructions may cause the processor 4422 to control the firing motor4402 to fire the plurality of staples 191 and/or advance the cuttingedge 182 in accordance with user input while the firing motor 4402 iscoupled to the module 4410.

In certain instances, one or more mechanisms and/or sensors such as, forexample, sensors 4430 can be employed to alert the processor 4422 to theprogram instructions that should be used in a particular setting. Forexample, the sensors 4430 may alert the processor 4422 to use theprogram instructions associated with articulation of the end effector300 while the module 4410 is coupled to the articulation motor 4406; andthe sensors 4430 may alert the processor 4422 to use the programinstructions associated with firing the surgical instrument 4400 whilethe module 4410 is coupled to the firing motor 4402. In certaininstances, the sensors 4430 may comprise position sensors which can beemployed to sense the position of the switch 4414, for example.Accordingly, the processor 4422 may use the program instructionsassociated with articulation of the end effector 300 upon detecting,through the sensors 4430 for example, that the switch 4414 is in thefirst position 4416; and the processor 4422 may use the programinstructions associated with firing the surgical instrument 4400 upondetecting, through the sensors 4430 for example, that the switch 4414 isin the second position 4418.

Referring now to FIG. 94, an outer casing of the surgical instrument4400 is removed and several features and elements of the surgicalinstrument 4400 are also removed for clarity of disclosure. Asillustrated in FIG. 94, the surgical instrument 4400 may include aplurality of sensors which can be employed to perform various functionsin connection with the operation of the surgical instrument 4400. Forexample, as illustrated in FIG. 94, the surgical instrument 4400 mayinclude sensors A, B, and/or C. In certain instances, the sensor A canbe employed to perform a first function, for example; the sensor B canbe employed to perform a second function, for example; and the sensor Ccan be employed to perform a third function, for example. In certaininstances, the sensor A can be employed to sense a thickness of thetissue captured by the end effector 300 during a first segment of aclosure stroke; the sensor B can be employed to sense the tissuethickness during a second segment of the closure stroke following thefirst segment; and the sensor C can be employed to sense the tissuethickness during a third segment of the closure stroke following thesecond segment, for example. In certain instances, the sensors A, B, andC can be disposed along the end effector 300, for example.

In certain instances, the sensors A, B, and C can be arranged, asillustrated in FIG. 94, such that the sensor A is disposed proximal tothe sensor B, and the sensor C is disposed proximal to the sensor B, forexample. In certain instances, as illustrated in FIG. 94, the sensor Acan sense the tissue thickness of the tissue captured by the endeffector 300 at a first position; the sensor B can sense the tissuethickness of the tissue captured by the end effector 300 at a secondposition distal to the first position; and the sensor C can sense thetissue thickness of the tissue captured by the end effector 300 at athird position distal to the second position, for example. The readerwill appreciate that the sensors described herein are intended asexamples of the types of sensors which can be employed in connectionwith the present disclosure. Other suitable sensors and sensingarrangements can be employed by the present disclosure.

In certain instances, the surgical instrument 4400 may include a commoncontrol module 4450 which can be similar in many respects to the module4410. For example, the module 4450, like the module 4410, may comprisethe controller 4420, the processor 4422, and/or the memory 4424. Incertain instances, the power source 4428 can supply power to the module4450, for example. In certain instances, the surgical instrument 4400may include a plurality of sensors such as the sensors A, B, and C, forexample, which can activated to perform various functions in connectionwith the operation of the surgical instrument 4400. In certaininstances, one of the sensors A, B, and C, for example, can beindividually or separately activated to perform one or more functionswhile the other sensors remain inactive. In certain instances, aplurality of sensors of the surgical instrument 4400 such as, forexample, the sensors A, B, and C may share the module 4450. In certaininstances, only one of the sensors A, B, and C can be coupled to themodule 4450 at a time. In certain instances, the plurality of sensors ofthe surgical instrument 4400 can be individually and separatelycouplable to the module 4450, for example. In at least one example, themodule 4450 can be selectively switched between operable engagement withsensor A, Sensor B, and/or Sensor C.

In certain instances, as illustrated in FIG. 94, the module 4450 can bedisposed in the handle 14, for example, and the sensors that share themodule 4450 can be disposed in the end effector 300, for example. Thereader will appreciate that the module 4450 and/or the sensors thatshare the module 4450 are not limited to the above identified positions.In certain instances, the module 4450 and the sensors that share themodule 4450 can be disposed in the end effector 300, for example. Otherarrangements for the positions of the module 4450 and/or the sensorsthat share the module 4450 are contemplated by the present disclosure.

In certain instances, as illustrated in FIG. 94, an interface 4452 canbe employed to manage the coupling and/or decoupling of the sensors ofthe surgical instrument 4400 to the module 4450. In certain instances,the interface 4452 can be selectively transitioned between a pluralityof positions and/or states. In a first position and/or state, theinterface 4452 may couple the module 4450 to the sensor A, for example;in a second position and/or state, the interface 4452 may couple themodule 4450 to the sensor B, for example; and in a third position and/orstate, the interface 4452 may couple the module 4450 to the sensor C,for example. Additional positions and/or states of the interface 4452are contemplated by the present disclosure.

In certain instances, the interface 4452 is movable between a firstposition, a second position, and/or a third position, for example,wherein the module 4450 is coupled to a first sensor in the firstposition, a second sensor in the second position, and a third sensor inthe third position. In certain instances, the module 4450 is decoupledfrom first sensor as the interface 4452 is moved from the firstposition; the module 4450 is decoupled from second sensor as theinterface 4452 is moved from the second position; and the module 4450 isdecoupled from third sensor as the interface 4452 is moved from thethird position. In certain instances, a switch or a trigger can beconfigured to transition the interface 4452 between the plurality ofpositions and/or states. In certain instances, a trigger can be movableto simultaneously effectuate the end effector and transition the controlmodule 4450 from operable engagement with one of the sensors that sharethe module 4450 to operable engagement with another one of the sensorsthat share the module 4450, for example.

In at least one example, as illustrated in FIG. 94, the closure trigger32 can be operably coupled to the interface 4450 and can be configuredto transition the interface 4450 between a plurality of positions and/orstates. As illustrated in FIG. 94, the closure trigger 32 can bemoveable between a plurality of positions, for example during a closurestroke, to transition the interface 4450 between a first position and/orstate wherein the module 4450 is electrically coupled to the sensor A,for example, a second position and/or state wherein the module 4450 iselectrically coupled to the sensor B, for example, and/or a thirdposition and/or state wherein the module 4450 is electrically coupled tothe sensor C, for example.

In certain instances, a user may actuate the closure trigger 32 tocapture tissue by the end effector 300. Actuation of the closure triggermay cause the interface 4452 to be transitioned or shifted to transitionthe module 4450 from operable engagement with the sensor A, for example,to operable engagement with the sensor B, for example, and/or fromoperable engagement with sensor B, for example, to operable engagementwith sensor C, for example.

In certain instances, the module 4450 may be coupled to the sensor Awhile the trigger 32 is in a first actuated position. As the trigger 32is actuated past the first actuated position and toward a secondactuated position, the module 4450 may be decoupled from the sensor A.Alternatively, the module 4450 may be coupled to the sensor A while thetrigger 32 is in an unactuated position. As the trigger 32 is actuatedpast the unactuated position and toward a second actuated position, themodule 4450 may be decoupled from the sensor A. In certain instances,the module 4450 may be coupled to the sensor B while the trigger 32 isin the second actuated position. As the trigger 32 is actuated past thesecond actuated position and toward a third actuated position, themodule 4450 may be decoupled from the sensor B. In certain instances,the module 4450 may be coupled to the sensor C while the trigger 32 isin the third actuated position.

In certain instances, as illustrated in FIG. 94, the module 4450 mayinclude a plurality of electrical and/or mechanical contacts 4451adapted for coupling engagement with the interface 4452. The pluralityof sensors of the surgical instrument 4400, which share the module 4450,may each comprise one or more corresponding electrical and/or mechanicalcontacts 4453 adapted for coupling engagement with the interface 4452,for example.

In certain instances, the processor 4422 may receive input from theplurality of sensors that share the module 4450 while the sensors arecoupled to the module 4452. For example, the processor 4422 may receiveinput from the sensor A while the sensor A is coupled to the module4450; the processor 4422 may receive input from the sensor B while thesensor B is coupled to the module 4450; and the processor 4422 mayreceive input from the sensor C while the sensor C is coupled to themodule 4450. In certain instances, the input can be a measurement valuesuch as, for example, a measurement value of a tissue thickness oftissue captured by the end effector 300. In certain instances, theprocessor 4422 may store the input from one or more of the sensors A, B,and C on the memory 4426. In certain instances, the processor 4422 mayperform various calculations based on the input provided by the sensorsA, B, and C, for example.

Local Display of Tissue Parameter Stabilization

FIGS. 95A and 95B illustrate one embodiment of an end effector 5300comprising a staple cartridge 5306 that further comprises twolight-emitting diodes (LEDs) 5310. The end effector 5300 is similar tothe end effector 300 described above. The end effector comprises a firstjaw member or anvil 5302, pivotally coupled to a second jaw member orelongated channel 5304. The elongated channel 5304 is configured toreceive the staple cartridge 5306 therein. The staple cartridge 5306comprises a plurality of staples (not shown). The plurality of staplesare deployable from the staple cartridge 5306 during a surgicaloperation. The staple cartridge 5306 further comprises two LEDs 5310mounted on the upper surface, or cartridge deck 5308 of the staplecartridge 5306. The LEDs 5310 are mounted such that they will be visiblewhen the anvil 5304 is in a closed position. Furthermore, the LEDs 5310can be sufficiently bright to be visible through any tissue that may beobscuring a direct view of the LEDs 5310. Additionally, one LED 5310 canbe mounted on either side of the staple cartridge 5306 such that atleast one LED 5310 is visible from either side of the end effector 5300.The LED 5310 can be mounted near the proximal end of the staplecartridge 530, as illustrated, or may be mounted at the distal end ofthe staple cartridge 5306.

The LEDs 5310 may be in communication with a processor ormicrocontroller, such as for instance microcontroller 1500 of FIG. 19.The microcontroller 1500 can be configured to detect a property oftissue compressed by the anvil 5304 against the cartridge deck 5308.Tissue that is enclosed by the end effector 5300 may change height asfluid within the tissue is exuded from the tissue's layers. Stapling thetissue before it has sufficiently stabilized may affect theeffectiveness of the staples. Tissue stabilization is typicallycommunicates as a rate of change, where the rate of change indicates howrapidly the tissue enclosed by the end effector is changing height.

The LEDs 5310 mounted to the staple cartridge 5306, in the view of theoperator of the instrument, can be used to indicate rate at which theenclosed tissue is stabilizing and/or whether the tissue has reached astable state. The LEDs 5310 can, for example, be configured to flash ata rate that directly correlates to the rate of stabilization of thetissue, that is, can flash quickly initially, flash slower as the tissuestabilizes, and remain steady when the tissue is stable. Alternatively,the LEDs 5310 can flash slowly initially, flash more quickly as thetissue stabilizes, and turn off when the tissue is stable.

The LEDs 5310 mounted on the staple cartridge 5306 can be usedadditionally or optionally to indicate other information. Examples ofother information include, but are not limited to: whether the endeffector 5300 is enclosing a sufficient amount of tissue, whether thestaple cartridge 5306 is appropriate for the enclosed tissue, whetherthere is more tissue enclosed than is appropriate for the staplecartridge 5306, whether the staple cartridge 5306 is not compatible withthe surgical instrument, or any other indicator that would be useful tothe operator of the instrument. The LEDs 5310 can indicate informationby either flashing at a particular rate, turning on or off at aparticular instance, lighting in different colors for differentinformation. The LEDs 5310 can alternatively or additionally be used toilluminate the area of operation. In some embodiments the LEDs 5310 canbe selected to emit ultraviolet or infrared light to illuminateinformation not visible under normal light, where that information isprinted on the staple cartridge 5300 or on a tissue compensator (notillustrated). Alternatively or additionally, the staples can be coatedwith a fluorescing dye and the wavelength of the LEDs 5310 chosen sothat the LEDs 5310 cause the fluorescing dye to glow. By illuminatingthe staples with the LEDs 5310 allows the operator of the instrument tosee the staples after they have been driven.

Returning to FIGS. 95A and 95B, FIG. 95A illustrates a side angle viewof the end effector 5300 with the anvil 5304 in a closed position. Theillustrated embodiment comprises, by way of example, one LED 5310located on either side of the cartridge deck 5308. FIG. 95B illustratesa three-quarter angle view of the end effector 5300 with the anvil 5304in an open position, and one LED 5310 located on either side of thecartridge deck 5308.

FIGS. 96A and 96B illustrate one embodiment of the end effector 5300comprising a staple cartridge 5356 that further comprises a plurality ofLEDs 5360. The staple cartridge 5356 comprises a plurality of LEDs 5360mounted on the cartridge deck 5358 of the staple cartridge 5356. TheLEDs 5360 are mounted such that they will be visible when the anvil 5304is in a closed position. Furthermore, the LEDs6 530 can be sufficientlybright to be visible through any tissue that may be obscuring a directview of the LEDs 5360. Additionally, the same number of LEDs 5360 can bemounted on either side of the staple cartridge 5356 such that the samenumber of LEDs 5360 is visible from either side of the end effector5300. The LEDs 5360 can be mounted near the proximal end of the staplecartridge 5356, as illustrated, or may be mounted at the distal end ofthe staple cartridge 5356.

The LEDs 5360 may be in communication with a processor ormicrocontroller, such as for instance microcontroller 1500 of FIG. 15.The microcontroller 1500 can be configured to detect a property oftissue compressed by the anvil 5304 against the cartridge deck 5358,such as the rate of stabilization of the tissue, as described above. TheLEDs 5360 can be used to indicate the rate at which the enclose tissueis stabilizing and/or whether the tissue has reached a stable state. TheLEDs 5360 can be configured, for instance, to light in sequence startingat the proximal end of the staple cartridge 5356 with each subsequentLED 5360 lighting at the rate at which the enclosed tissue isstabilizing; when the tissue is stable, all the LEDs 5360 can be lit.Alternatively, the LEDs 5360 can light in sequence beginning at thedistal end of the staple cartridge 5356. Yet another alternative is forthe LEDs 5360 to light in a sequential, repeating sequence, with thesequence starting at either the proximal or distal end of the LEDs 5360.The rate at which the LEDs 5360 light and/or the speed of the repeat canindicate the rate at which the enclosed tissue is stabilizing. It isunderstood that these are only examples of how the LEDs 5360 canindicate information about the tissue, and that other combinations ofthe sequence in which the LEDs 5360 light, the rate at which they light,and or their on or off state are possible. It is also understood thatthe LEDs 5360 can be used to communicate some other information to theoperator of the surgical instrument, or to light the work area, asdescribed above.

Returning to FIGS. 96A and 96B, FIG. 96A illustrates a side angle viewof the end effector 5300 with the anvil 5304 in a closed position. Theillustrated embodiment comprises, by way of example, a plurality of LEDs5360 located on either side of the cartridge deck 5358. FIG. 96Billustrates a three-quarter angle view of the end effector 5300 with theanvil 5304 in an open position, illustrating a plurality of LEDs 5360located on either side of the cartridge deck 5358.

FIGS. 97A and 97B illustrate one embodiment of the end effector 5300comprising a staple cartridge 5406 that further comprises a plurality ofLEDs 5410. The staple cartridge 5406 comprises a plurality of LEDs 5410mounted on the cartridge deck 5408 of the staple cartridge 5406, withthe LEDs 5410 placed continuously from the proximal to the distal end ofthe staple cartridge 5406. The LEDs 5410 are mounted such that they willbe visible when the anvil 5302 is in a closed position. The same numberof LEDs 5410 can be mounted on either side of the staple cartridge 5406such that the same number of LEDs 5410 is visible from either side ofthe end effector 5300.

The LEDs 5410 can be in communication with a processor ormicrocontroller, such as for instance microcontroller 1500 of FIG. 15.The microcontroller 1500 can be configured to detect a property oftissue compressed by the anvil 5304 against the cartridge deck 5408,such as the rate of stabilization of the tissue, as described above. TheLEDs 5410 can be configured to be turned on or off in sequences orgroups as desired to indicate the rate of stabilization of the tissueand/or that the tissue is stable. The LEDs 5410 can further beconfigured communicate some other information to the operator of thesurgical instrument, or to light the work area, as described above.Additionally or alternatively, the LEDs 5410 can be configured toindicate which areas of the end effector 5300 contain stable tissue, andor what areas of the end effector 5300 are enclosing tissue, and/or ifthose areas are enclosing sufficient tissue. The LEDs 5410 can furtherbe configured to indicate if any portion of the enclosed tissue isunsuitable for the staple cartridge 5406.

Returning to FIGS. 97A and 97B, FIG. 97A illustrates a side angle viewof the end effector 5300 with the anvil 5304 in a closed position. Theillustrated embodiment comprises, by way of example, a plurality of LEDs5410 from the proximal to the distal end of the staple cartridge 5406,on either side of the cartridge deck 5408. FIG. 97B illustrates athree-quarter angle view of the end effector 5300 with the anvil 5304 inan open position, illustrating a plurality of LEDs 5410 from theproximal to the distal end of the staple cartridge 5406, and on eitherside of the cartridge deck 5408.

Adjunct with Integrated Sensors to Quantify Tissue Compression

FIG. 98A illustrates an embodiment of an end effector 5500 comprising atissue compensator 5510 that further comprises a layer of conductiveelements 5512. The end effector 5500 is similar to the end effector 300described above. The end effector 5500 comprises a first jaw member, oranvil, 5502 pivotally coupled to a second jaw member 5504 (not shown).The second jaw member 5504 is configured to receive a staple cartridge5506 therein (not shown). The staple cartridge 5506 comprises aplurality of staples (not shown). The plurality of staples 191 isdeployable from the staple cartridge 3006 during a surgical operation.In some embodiments, the end effector 5500 further comprises a tissuecompensator 5510 removably positioned on the anvil 5502 or on the staplecartridge 5506. FIG. 98B illustrates a detail view of a portion of thetissue compensator 5510 shown in FIG. 98A.

As described above, the plurality of staples 191 can be deployed betweenan unfired position and a fired position, such that staple legs 5530move through and penetrate tissue 5518 compressed between the anvil 5502and the staple cartridge 5506, and contact the anvil's 5502staple-forming surface. In embodiments that include a tissue compensator5510, the staple legs 5530 also penetrate and puncture the tissuecompensator 5510. As the staple legs 5530 are deformed against theanvil's staple-forming surface, each staple 191 can capture a portion ofthe tissue 5518 and the tissue compensator 5510 and apply a compressiveforce to the tissue 5518. The tissue compensator 5510 thus remains inplace with the staples 191 after the surgical instrument 10 is withdrawnfrom the patient's body. Because they are to be retained by thepatient's body, the tissue compensators 5510 are composed of biodurableand/or biodegradable materials. The tissue compensators 5510 aredescribed in further detail in U.S. Pat. No. 8,657,176, entitled TISSUETHICKNESS COMPENSATOR FOR SURGICAL STAPLER, which is incorporated hereinby reference in its entirety.

Returning to FIG. 98A, in some embodiments, the tissue compensator 5510comprises a layer of conductive elements 5512. The conductive elements5512 can comprise any combination of conductive materials in any numberof configurations, such as for instance coils of wire, a mesh or grid ofwires, conductive strips, conductive plates, electrical circuits,microprocessors, or any combination thereof. The layer containingconductive elements 5512 can be located on the anvil-facing surface 5514of the tissue compensator 5510. Alternatively or additionally, the layerof conductive elements 5512 can be located on the staplecartridge-facing surface 5516 of the tissue compensator 5510.Alternatively or additionally, the layer of conductive elements 5512 canbe embedded within the tissue compensator 5510. Alternatively, the layerof conductive elements 5512 can comprise all of the tissue compensator5510, such as when a conductive material is uniformly or non-uniformlydistributed in the material comprising the tissue compensator 5510.

FIG. 98A illustrates an embodiment wherein the tissue compensator 5510is removably attached to the anvil 5502 portion of the end effector5500. The tissue compensator 5510 would be so attached before the endeffector 5500 would be inserted into a patient's body. Additionally oralternatively, a tissue compensator 5610 can be attached to a staplecartridge 5506 (not illustrated) after or before the staple cartridge5506 is applied to the end effector 6600 and before the device isinserted into a patient's body

FIG. 99 illustrates various example embodiments that use the layer ofconductive elements 5512 and conductive elements 5524, 5526, and 5528 inthe staple cartridge 5506 to detect the distance between the anvil 5502and the upper surface of the staple cartridge 5506.

The distance between the anvil 5502 and the staple cartridge 5506indicates the amount and/or density of tissue 5518 compressedtherebetween. This distance can additionally or alternatively indicatewhich areas of the end effector 5500 contain tissue. The tissue 5518thickness, density, and/or location can be communicated to the operatorof the surgical instrument 10.

In the illustrated example embodiments, the layer of conductive elements5512 is located on the anvil-facing surface 5514 of the tissuecompensator 5510, and comprises one or more coils of wire 5522 incommunication with a microprocessor 5520. The microprocessor 5500 can belocated in the end effector 5500 or any component thereof, or can belocated in the housing 12 of the instrument, or can comprise anymicroprocessor or microcontroller previously described. In theillustrated example embodiments, the staple cartridge 5506 also includesconductive elements, which can be any one of: one or more coils of wire5524, one or more conductive plates 5526, a mesh of wires 5528, or anyother convenient configuration, or any combination thereof. The staplecartridge's 5506 conductive elements can be in communication with thesame microprocessor 5520 or some other microprocessor in the instrument.

When the anvil 5502 is in a closed position and thus is compressingtissue 5518 against staple cartridge 5506, the layer of conductiveelements 5512 of the tissue compensator 5510 can capacitively couplewith the conductors in staple cartridge 5506. The strength of thecapacitive field between the layer of conductive elements 5512 and theconductive elements of the staple cartridge 5506 can be used todetermine the amount of tissue 5518 being compressed. Alternatively, thestaple cartridge 5506 can comprise eddy current sensors in communicationwith a microprocessor 5520, wherein the eddy current sensors areoperable to sense the distance between the anvil 5502 and the uppersurface of the staple cartridge 5506 using eddy currents.

It is understood that other configurations of conductive elements arepossible, and that the embodiments of FIG. 99 are by way of exampleonly, and not limitation. For example, in some embodiments the layer ofconductive elements 5512 can be located on the staple cartridge-facingsurface 5516 of the tissue compensator 5510. Also, in some embodimentsthe conductive elements 5524, 5526, and/or 5528 can be located on orwithin the anvil 5502. Thus in some embodiments, the layer of conductiveelements 5512 can capacitively couple with conductive elements in theanvil 5502 and thereby sense properties of tissue 5518 enclosed withinthe end effector.

It can also be recognized that tissue compensator 5512 can comprise alayer of conductive elements 5512 on both the anvil-facing surface 5514and the cartridge-facing surface 5516. A system to detect the amount,density, and/or location of tissue 5518 compressed by the anvil 5502against the staple cartridge 5506 can comprise conductors or sensorseither in the anvil 5502, the staple cartridge 5506, or both.Embodiments that include conductors or sensors in both the anvil 5502and the staple cartridge 5506 can optionally achieve enhanced results byallowing differential analysis of the signals that can be achieved bythis configuration.

FIGS. 100A and 100B illustrate an embodiment of the tissue compensator5510 comprising a layer of conductive elements 5512 in operation. FIG.100A illustrates one of the plurality of staples 191 after it has beendeployed. As illustrated, the staple 191 has penetrated both the tissue5518 and the tissue compensator 5510. The layer of conductive elements5512 may comprise, for example, mesh wires. Upon penetrating the layerof conductive elements 5512, the staple legs 5530 may puncture the meshof wires, thus altering the conductivity of the layer of conductiveelements 5512. This change in the conductivity can be used to indicatethe locations of each of the plurality of staples 191. The location ofthe staples 191 can compared against the expected location of thestaples, and this comparison can be used to determine if any staples didnot fire or if any staples are not where they are expected to be.

FIG. 100A also illustrates staple legs 5530 that failed to completelydeform. FIG. 100B illustrates staple legs 5530 that have properly andcompletely deformed. As illustrated in FIG. 100B, the layer ofconductive elements 5512 can be punctured by the staple legs 5530 asecond time, such as when the staple legs 5530 deform against thestaple-forming surface of the anvil 5502 and turn back towards thetissue 5518. The secondary breaks in the layer of conductive elements5512 can be used to indicate complete staple 191 formation, asillustrated in FIG. 100B, or incomplete staple 191 formation, as in FIG.100A.

FIGS. 101A and 101B illustrate an embodiment of an end effector 5600comprising a tissue compensator 5610 further comprising conductors 5620embedded within. The end effector 5600 comprises a first jaw member, oranvil, 5602 pivotally coupled to a second jaw member 5604. The secondjaw member 5604 is configured to receive a staple cartridge 5606therein. In some embodiments, the end effector 5600 further comprises atissue compensator 5610 removably positioned on the anvil 5602 or thestaple cartridge 5606.

Turning first to FIG. 4B, FIG. 4B illustrates a cutaway view of thetissue compensator 5610 removably positioned on the staple cartridge5606. The cutaway view illustrates an array of conductors 5620 embeddedwithin the material that comprises the tissue compensator 5610. Thearray of conductors 5620 can be arranged in an opposing configuration,and the opposing elements can be separated by insulating material. Thearray of conductors 5620 are each coupled to one or more conductivewires 5622. The conductive wires 5622 allow the array of conductors 5620to communicate with a microprocessor, such as for instancemicroprocessor 1500. The array of conductors 5620 may span the width ofthe tissue compensator 5610 such that they will be in the path of acutting member or knife bar 280. As the knife bar 280 advances, it willsever, destroy, or otherwise disable the conductors 5620, and therebyindicate its position within the end effector 5600. The array ofconductors 5610 can comprise conductive elements, electric circuits,microprocessors, or any combination thereof.

Turning now to FIG. 101A, FIG. 101A illustrates a close-up cutaway viewof the end effector 5600 with the anvil 5602 in a closed position. In aclosed position, the anvil 5602 can compress tissue 5618 and the tissuecompensator 5610 against the staple cartridge 5606. In some cases, onlya part of the end effector 5600 may be enclosing the tissue 5618. Inareas of the end effector 5600 that are enclosing tissue 5618, thetissue compensator 5610 may be compressed 5624 a greater amount thanareas that do not enclose tissue 5618, where the tissue compensator 5618may remain uncompressed 5626 or be less compressed. In areas of greatercompression 5624, the array of conductors 5620 will also be compressed,while in uncompressed 5626 areas, the array of conductors 5620 will befurther apart. Hence, the conductivity, resistance, capacitance, and/orsome other electrical property between the array of conductors 5620 canindicate which areas of the end effector 5600 contain tissue.

FIGS. 102A and 102B illustrate an embodiment of an end effector 5650comprising a tissue compensator 5660 further comprising conductors 5662embedded therein. The end effector 5650 comprises a first jaw member, oranvil, 5652 pivotally coupled to a second jaw member 5654. The secondjaw member 5654 is configured to receive a staple cartridge 5656therein. In some embodiments, the end effector 5650 further comprises atissue compensator 5660 removably positioned on the anvil 5652 or thestaple cartridge 5656.

FIG. 102A illustrates a cutaway view of the tissue compensator 5660removably positioned on the staple cartridge 5656. The cutaway viewillustrates conductors 5670 embedded within the material that comprisesthe tissue compensator 5660. Each of the conductors 5672 is coupled to aconductive wire 5672. The conductive wires 5672 allow the array ofconductors 5672 to communicate with a microprocessor, such as forinstance microprocessor 1500. The conductors 5672 may compriseconductive elements, electric circuits, microprocessors, or anycombination thereof.

FIG. 102A illustrates a close-up side view of the end effector 5650 withthe anvil 5652 in a closed position. In a closed position, the anvil5652 can compress tissue 5658 and the tissue compensator 5660 againstthe staple cartridge 5656. The conductors 5672 embedded within thetissue compensator 5660 can be operable to apply pulses of electricalcurrent 5674, at predetermined frequencies, to the tissue 5658. The sameor additional conductors 5672 ca detect the response of the tissue 5658and transmit this response to a microprocessor or microcontrollerlocated in the instrument. The response of the tissue 5658 to theelectrical pulses 5674 can be used to determine a property of the tissue5658. For example, the galvanic response of the tissue 5658 indicatesthe tissue's 5658 moisture content. As another example, measurement ofthe electrical impedance through the tissue 5658 could be used todetermine the conductivity of the tissue 5648, which is an indicator ofthe tissue type. Other properties that can be determined include by wayof example and not limitation: oxygen content, salinity, density, and/or the presence of certain chemicals. By combining data from severalsensors, other properties could be determined, such as blood flow, bloodtype, the presence of antibodies, etc.

FIG. 103 illustrates an embodiment of a staple cartridge 5706 and atissue compensator 5710 wherein the staple cartridge 5706 provides powerto the conductive elements 5720 that comprise the tissue compensator5710. As illustrated, the staple cartridge 5706 comprises electricalcontacts 5724 in the form of patches, spokes, bumps, or some otherraised configuration. The tissue compensator 5710 comprises mesh orsolid contact points 5722 that can electrically couple to the contacts5724 on the staple cartridge 5706.

FIGS. 104A and 104B illustrate an embodiment of a staple cartridge 5756and a tissue compensator 5760 wherein the staple cartridge providespower to the conductive elements 5770 that comprise the tissuecompensator 5710. As illustrated in FIG. 104A, the tissue compensator5760 comprises an extension or tab 5772 configured to come into contactwith the staple cartridge 5756. The tab 5772 may contact and adhere toan electrical contact (not shown) on the staple cartridge 5756. The tab5772 further comprises a break point 5774 located in a wire comprisingthe conductive elements 5770 of the tissue compensator 5760. When thetissue compensator 5760 is compressed, such as when an anvil is in aclosed position towards the staple cartridge 5756, the break point 5774will break, thus allowing the tissue compensator 5756 to become freefrom the staple cartridge 5756. FIG. 104B illustrates another embodimentemploying a break point 5774 positioned in the tab 5772.

FIGS. 105A and 105B illustrate an embodiment of an end effector 5800comprising position sensing elements 5824 and a tissue compensator 5810.The end effector 5800 comprises a first jaw member, or anvil, 5802pivotally coupled to a second jaw member 5804 (not shown). The secondjaw member 5804 is configured to receive a staple cartridge 5806 (notshown) therein. In some embodiments, the end effector 5800 furthercomprises a tissue compensator 5810 removably positioned on the anvil5802 or the staple cartridge 5806.

FIG. 105A illustrates the anvil 5804 portion of the end effector 5800.In some embodiments the anvil 5804 comprises position sensing elements5824. The position sensing elements 5824 can comprise, for example,electrical contacts, magnets, RF sensors, etc. The position sensingelements 5824 can be located in key locations, such as for instance thecorner points where the tissue compensator 5810 will be attached, oralong the exterior edges of the anvil's 5802 tissue-facing surface. Insome embodiments, the tissue compensator 5810 can comprise positionindicating elements 5820. The position indicating elements 5820 can belocated in corresponding locations to the position sensing elements 5824on the anvil 5802, or in proximal locations, or in overlappinglocations. The tissue compensator 5810 optionally further comprises alayer of conductive elements 5812. The layer of conductive elements 5812and/or the position indicating elements 5820 can be electrically coupledto conductive wires 5822. The conductive wires 5822 can providecommunication with a microprocessor, such as for instance microprocessor1500.

FIG. 105B illustrates an embodiment the position sensing elements 5824and position indicating elements 5820 in operation. When the tissuecompensator 5810 is positioned, the anvil 5802 can sense 5826 that thetissue compensator 5810 is properly position. When the tissuecompensator 5810 is misaligned or missing entirely, the anvil 5802 (orsome other component) can sense 5826 that the tissue compensator 5810 ismisaligned. If the misalignment is above a threshold magnitude, awarning can be signaled to the operator of the instrument, and/or afunction of the instrument can be disabled to prevent the staples frombeing fired.

In FIGS. 105A and 105B the position sensing elements 5824 areillustrated as a part of the anvil 5804 by way of example only. It isunderstood that the position sensing elements 5824 can be locatedinstead or additionally on the staple cartridge 5806. It is alsounderstood that the location of the position sensing elements 5824 andthe position indicating elements 5820 can be reversed, such that thetissue compensator 5810 is operable to indicate whether it is properlyaligned.

FIGS. 106A and 106B illustrate an embodiment of an end effector 5850comprising position sensing elements 5874 and a tissue compensator 5860.The end effector 5850 comprises a first jaw member, or anvil, 5852pivotally coupled to a second jaw member 5854 (not shown). The secondjaw member 5854 is configured to receive a staple cartridge 5856 (notshow) therein. In some embodiments, the end effector 5850 furthercomprises a tissue compensator 5860 removably positioned on the anvil5852 or the staple cartridge 5856.

FIG. 106A illustrates the anvil 5852 portion of the end effector 5850.In some embodiments, the anvil 5854 comprises an array of conductiveelements 5474. The array of conductive elements 5474 can comprise, forexample, electrical contacts, magnets, RF sensors, etc. The array ofconductive elements 5474 are arrayed along the length of thetissue-facing surface of the anvil 5852. In some embodiments, the tissuecompensator 5860 can comprise a layer of conductive elements 5862,wherein the conductive elements comprise a grid or mesh of wires. Thelayer of conductive elements 5862 may be coupled to conductive wires5876. The conductive wires 5862 can provide communication with amicroprocessor, such as for instance microprocessor 1500.

FIG. 106A illustrates an embodiment wherein of the conductive elements5474 of the anvil 5852 and the layer of conductive elements 5862 areoperable to indicate whether the tissue compensator 5860 is misalignedor missing. As illustrated, the array of conductive elements 5874 isoperable to electrically couple with the layer of conductive elements5862. When the tissue compensator 5860 is misaligned or missing, theelectrical coupling will be incomplete. If the misalignment is above athreshold magnitude, a warning can be signaled to the operator of theinstrument, and/or a function of the instrument can be disabled toprevent the staples from being fired.

It is understood that the array of conductive elements 5874 mayadditionally or alternatively be located on the staple cartridge 5856.It is also understood that the any of the anvil 5852, staple cartridge5856, and/or tissue compensator 5860 may be operable to indicatemisalignment of the tissue compensator 5860.

FIGS. 107A and 107B illustrate an embodiment of a staple cartridge 5906and a tissue compensator 5910 that is operable to indicate the positionof a cutting member or knife bar 280. FIG. 107A is a top-down view ofthe staple cartridge 5906 that has a tissue compensator 5920 placed onits upper surface 5916. The staple cartridge 5906 further comprises acartridge channel 5918 operable to accept a cutting member or knife bar280. FIG. 107A illustrates only the layer of conductive elements 5922 ofthe tissue compensator 5910, for clarity. As illustrated, the layer ofconductive elements 5922 comprises a lengthwise segment 5930 that islocated off-center. The lengthwise segment 5930 is coupled to conductivewires 5926. The conductive wires 5926 allow the layer of conductiveelements 5922 to communicate with a microprocessor, such as for instancemicroprocessor 1500.The layer of conductive elements 5922 furthercomprises horizontal elements 5932 coupled to the lengthwise segment5930 and spanning the width of the tissue compensator 5910, and thuscrossing the path of the knife bar 280. As the knife bar 280 advances,it will sever the horizontal elements 5932 and thereby alter anelectrical property of the layer of conductive elements 5922. Forexample, the advancing of the knife bar 280 may alter the resistance,capacitance, conductivity, or some other electrical property of thelayer of conductive elements 5922. As each horizontal element 5932 issevered by the knife bar 280, the change in the electrical properties ofthe layer of conductive elements 5922 will indicate the position of theknife bar 280.

FIG. 107B illustrates an alternate configuration for the layer ofconductive elements 5922. As illustrated, the layer of conductiveelements 5922 comprises a lengthwise segment 5934 on either side of thecartridge channel 5918. The layer of conductive elements 5922 furthercomprises horizontal elements 5936 coupled to both of the lengthwisesegments 5934, thus spanning the path of the knife bar 280. As the knifebar 280, the resistance, for example between the knife bar and thehorizontal elements 5396 can be measured and used to determine thelocation of the knife bar 280. Other configurations of the layer ofconductive elements 5922 can be used to accomplish the same result, suchas for instance any of the arrangements illustrated in FIGS. 98A through102B. For example, the layer of conductive elements 5922 can comprise awire mesh or grid, such that as the knife bar 280 advances it can severthe wire mesh and thereby change the conductivity in the wire mesh. Thischange in conductivity can be used to indicate the position of the knifebar 280.

Other uses for the layer of conductive elements 5922 can be imagined.For example, a specific resistance can be created in the layer ofconductive elements 592, or a binary ladder of resistors or conductorscan be implemented, such that simple data can be stored in the tissuecompensator 5910. This data can be extracted from the tissue compensator5910 by conductive elements in the anvil and/or staple cartridge wheneither electrically couple with the layer of conductive elements 5922.The data can represent, for example, a serial number, a “use by” date,etc.

Polarity of Hall Magnet to Detect Misloaded Cartridge

FIG. 108 illustrates one embodiment of an end effector 6000 comprising amagnet 6008 and a Hall effect sensor 6010 wherein the detected magneticfield 6016 can be used to identify a staple cartridge 6006. The endeffector 6000 is similar to the end effector 300 described above. Theend effector 6000 comprises a first jaw member or anvil 6002, pivotallycoupled to a second jaw member or elongated channel 6004. The elongatedchannel 6004 is configured to operably support a staple cartridge 6006therein. The staple cartridge 6006 is similar to the staple cartridge304 described above. The anvil 6002 further comprises a magnet 6008. Thestaple cartridge 6006 further comprises a Hall effect sensor 6010 and aprocessor 6012. The Hall effect sensor 6010 is operable to communicatewith the processor 6012 through a conductive coupling 6014. The Halleffect sensor 6010 is positioned within the staple cartridge 6006 tooperatively couple with the magnet 6008 when the anvil 6002 is in aclosed position. The Hall effect sensor 6010 can be operable to detectthe magnetic field 6016 produced by the magnet 6008. The polarity of themagnetic field 6016 can be one of north or south depending on theorientation of the magnet 6008 within the anvil 6002. In the illustratedembodiment of FIG. 108, the magnet 6008 is oriented such that its southpole is directed towards the staple cartridge 6006. The Hall effectsensor 6010 can be operable to detect the magnetic field 6016 producedby a south pole. If the Hall effect sensor 6010 detects a magnetic southpole, then the staple cartridge 6006 can be identified as of a firsttype.

FIG. 109 illustrates on embodiment of an end effector 6050 comprising amagnet 6058 and a Hall effect sensor 6060 wherein the detected magneticfield 6066 can be used to identify a staple cartridge 6056. The endeffector 6050 comprises a first jaw member or anvil 6052, pivotallycoupled to a second jaw member or elongated channel 6054. The elongatedchannel 6054 is configured to operably support a staple cartridge 6056therein. The anvil 6052 further comprises a magnet 6058. The staplecartridge 6056 further comprises a Hall effect sensor 6060 incommunication with a processor 6062 over a conductive coupling 6064. TheHall effect sensor 6060 is positioned such that it will operativelycouple with the magnet 6058 when the anvil 6052 is in a closed position.The Hall effect sensor 6060 can be operable to detect the magnetic field6066 produced by the magnet 6058. In the illustrated embodiment, themagnet 6058 is oriented such that its north magnetic pole is directedtowards the staple cartridge 6056. The Hall effect sensor 6060 can beoperable to detect the magnetic field 6066 produced by a north pole. Ifthe Hall effect sensor 6060 detects a north magnetic pole, then thestaple cartridge 6056 an be identified as a second type.

It can be recognized that the second type staple cartridge 6056 of FIG.109 can be substituted for the first type staple cartridge 6006 of FIG.108, and vice versa. In FIG. 108, the second type staple cartridge 6056would be operable to detect a magnetic north pole, but will detect amagnetic south pole instead. In this case, end effector 6000 willidentify the staple cartridge 6056 as being of the second type. If theend effector 6000 did not expect a staple cartridge 6056 of the secondtype, the operator of the instrument can be alerted, and/or a functionof the instrument can be disabled. The type of the staple cartridge 6056can additionally or alternatively be used to identify some parameter ofthe staple cartridge 6056, such as for instance the length of thecartridge and/or the height and length of the staples.

Similarly, as shown in FIG. 109, the first type staple cartridge 6006can be substituted for the second staple cartridge 6056. The first typestaple cartridge 6006 would be operable to detect a south magnetic pole,but will instead detect a north magnetic pole. In this case, the endeffector 6050 will identify the staple cartridge 6006 as being of thefirst type.

FIG. 110 illustrates a graph 6020 of the voltage 6022 detected by a Halleffect sensor located in the distal tip of a staple cartridge, such asis illustrated in FIGS. 108 and 109, in response to the distance or gap6024 between a magnet located in the anvil and the Hall effect sensor inthe staple cartridge, such as illustrated in FIGS. 108 and 109. Asillustrated FIG. 110, when the magnet in the anvil is oriented such thatits north pole is towards the staple cartridge, the voltage will tendtowards a first value as the magnet comes in proximity to the Halleffect sensor; when the magnet is oriented with its south pole towardsthe staple cartridge, the voltage will tend towards a second, differentvalue. The measured voltage can be used by the instrument to identifythe staple cartridge.

FIG. 111 illustrates one embodiment of the housing 6100 of the surgicalinstrument, comprising a display 6102. The housing 6100 is similar tothe housing 12 described above. The display 6102 can be operable toconvey information to the operator of the instrument, such as forinstance, that the staple cartridge coupled to the end effector isinappropriate for the present application. Additionally oralternatively, the display 6102 can display the parameters of the staplecartridge, such as the length of the cartridge and/or the height andlength of the staples.

FIG. 112 illustrates one embodiment of a staple retainer 6160 comprisinga magnet 6162. The staple retainer 6160 can be operably coupled to astaple cartridge 6156 and functions to prevent staples from exiting ofthe staple cartridge 6156. The staple retainer 6160 can be left in placewhen the staple cartridge 6156 is applied to an end effector. In someembodiments, the staple retainer 6160 comprises a magnet 6162 located inthe distal area of the staple retainer 6160. The anvil of the endeffector can comprise a Hall effect sensor operable to couple with themagnet 6162 in the staple retainer 6160. The Hall effect sensor can beoperable to detect the properties of the magnet 6162, such as forinstance the magnetic field strength and magnetic polarity. The magneticfield strength can be varied by, for example, placing the magnet 6162 indifferent locations and/or depths on or in the staple retainer 6160, orby selecting magnets 6162 of different compositions. The differentproperties of the magnet 6162 can be used to identify staple cartridgesof different types.

FIGS. 113A and 113B illustrate one embodiment of an end effector 6200comprising a sensor 6208 for identifying staple cartridges 6206 ofdifferent types. The end effector 6200 comprises a first jaw member oranvil 6202, pivotally coupled to a second jaw member or elongatedchannel 6204. The elongated channel 6204 is configured to operablysupport a staple cartridge 6206 therein. The end effector 6200 furthercomprises a sensor 6208 located in the proximal area. The sensor 6208can be any of an optical sensor, a magnetic sensor, an electricalsensor, or any other suitable sensor.

The sensor 6208 can be operable to detect a property of the staplecartridge 6206 and thereby identify the staple cartridge 6206 type. FIG.113B illustrates an example where the sensor 6208 is an optical emitterand detector 6210. The body of the staple cartridge 6206 can bedifferent colors, such that the color identifies the staple cartridge6206 type. An optical emitter and detector 6210 can be operable tointerrogate the color of the staple cartridge 6206 body. In theillustrated example, the optical emitter and detector 6210 can detectwhite 6212 by receiving reflected light in the red, green, and bluespectrums in equal intensity. The optical emitter and detector 6210 candetect red 6214 by receiving very little reflected light in the greenand blue spectrums while receiving light in the red spectrum in greaterintensity.

Alternately or additionally, the optical emitter and detector 6210, oranother suitable sensor 6208, can interrogate and identify some othersymbol or marking on the staple cartridge 6206. The symbol or markingcan be any one of a barcode, a shape or character, a color-coded emblem,or any other suitable marking. The information read by the sensor 6208can be communicated to a microcontroller in the surgical device 10, suchas for instance microcontroller 1500. The microcontroller 1500 can beconfigured to communicate information about the staple cartridge 6206 tothe operator of the instrument. For instance, the identified staplecartridge 6206 may not be appropriate for a given application; in suchcase, the operator of the instrument can be informed, and/or a functionof the instrument s inappropriate. In such instance, microcontroller1500 can optionally be configured to disable a function of surgicalinstrument can be disabled. Alternatively or additionally,microcontroller 1500 can be configured to inform the operator of thesurgical instrument 10 of the parameters of the identified staplecartridge 6206 type, such as for instance the length of the staplecartridge 6206, or information about the staples, such as the height andlength.

Smart Cartridge Wake Up Operation and Data Retention

In one embodiment the surgical instrument described herein comprisesshort circuit protection techniques for sensors and/or electroniccomponents. To enable such sensors and other electronic technology bothpower and data signals are transferred between modular components of thesurgical instrument. During assembly of modular sensor componentselectrical conductors that when connected are used to transfer power anddata signals between the connected components are typically exposed.

FIG. 114 is a partial view of an end effector 7000 with electricalconductors 7002, 7004 for transferring power and data signals betweenthe connected components of the surgical instrument according to oneembodiment. There is potential for these electrical conductors 7002,7004 to become shorted and thus damage critical system electroniccomponents. FIG. 115 is a partial view of the end effector 7000 shown inFIG. 114 showing sensors and/or electronic components 7005 located inthe end effector. With reference now to both FIGS. 114 and 115, invarious embodiments the surgical instruments disclosed throughout thepresent disclosure provide real time feedback about the compressibilityand thickness of tissue using electronic sensors. Modular architectureswill enable the configuration of custom modular shafts to employ jobspecific technologies. To enable sensors and other electronic circuitcomponents in surgical instruments it is necessary to transfer bothpower and data signals between a secondary circuit comprising themodular sensor and/or electronic circuit components 7005. During theassembly of the modular sensors and/or electronic components 7005 theelectrical conductors 7002, 7004 are exposed such that when connected,they are used to transfer power and data signals between the connectedsensors and/or electronic components 7005. Because there is a potentialfor these electrical conductors 7002, 7004 to become short circuitedduring the assembly process and thus damage other system electroniccircuits, various embodiments of the surgical instruments describedherein comprise short circuit protection techniques for the sensorsand/or electronic components 7005

In one embodiment, the present disclosure provides a short circuitprotection circuit 7012 for the sensors and/or electronic components7005 of the secondary circuits of the surgical instrument. FIG. 116 is ablock diagram of a surgical instrument electronic subsystem 7006comprising a short circuit protection circuit 7012 for the sensorsand/or electronic components 7005 according to one embodiment. A mainpower supply circuit 7010 is connected to a primary circuit comprising amicroprocessor and other electronic components 7008 (processor 7008hereinafter) through main power supply terminals 7018, 7020. The mainpower supply circuit 7010 also is connected to a short circuitprotection circuit 7012. The short circuit protection circuit 7012 iscoupled to a supplementary power supply circuit 7014, which suppliespower to the sensors and/or electronic components 7005 via theelectrical conductors 7002, 7004.

To reduce damage to the processor 7008 connected to the main powersupply terminals 7018, 7020, during a short circuit between theelectrical conductors 7002, 7004 of the power supply terminals feedingthe sensors and/or electronic components 7005, a selfisolating/restoring short circuit protection circuit 7012 is provided.In one embodiment, the short circuit protection circuit 7012 may beimplemented by coupling a supplementary power supply circuit 7014 to themain power supply circuit 7010. In circumstances when the supplementarypower supply circuit 7014 power conductors 7002, 7004 are shorted, thesupplementary power supply circuit 7014 isolates itself from the mainpower supply circuit 7010 to prevent damage to the processor 7008 of thesurgical instrument. Thus, there is virtually no effect to the processor7008 and other electronic circuit components coupled to the main powersupply terminals 7018, 7020 when a short circuit occurs in theelectrical conductors 7002, 7004 of the supplementary power supplycircuit 7014. Accordingly, in the event that a short circuit occursbetween the electrical conductors 7002, 7004 of the supplementary powersupply circuit 7014, the main power supply circuit 7010 is unaffectedand remains active to supply power to the protected processor 7008 suchthat the processor 7008 can monitor the short circuit condition. Whenthe short circuit between the electrical conductors 7002, 7004 of thesupplementary power supply circuit 7014 is remedied, the supplementarypower supply circuit 7014 rejoins the main power supply circuit 7010 andis available once again to supply power to the sensor components 7005.The short circuit protection circuit 7012 also may be monitored toindicate one or more short circuit conditions to the end user of thesurgical instrument. The short circuit protection circuit 7012 also maybe monitored to lockout the firing of the surgical instrument when ashort circuit event is indicated. Many supplementary protection circuitsmay be networked together to isolate, detect, or protect other circuitfunctions.

Accordingly, in one aspect, the present disclosure provides a shortcircuit protection circuit 7012 for electrical conductors 7002, 7004 inthe end effector 7000 (FIGS. 114 and 115) or other elements of thesurgical instrument. In one embodiment, the short circuit protectioncircuit 7012 employs a supplementary self-isolating/restoring powersupply circuit 7014 coupled to the main power supply circuit 7010. Theshort circuit protection circuit 7012 may be monitored to indicate oneor more short circuit conditions to the end user of the surgicalinstrument. In the event of a short circuit, the short circuitprotection circuit 7012 may be employed to lock-out the surgicalinstrument from being fired or other device operations. Many othersupplementary protection circuits may be networked together to isolate,detect, or protect other circuit functions.

FIG. 117 is a short circuit protection circuit 7012 comprising asupplementary power supply circuit 7014 coupled to a main power supplycircuit 7010, according to one embodiment. The main power supply circuit7010 comprises a transformer 7023 (X1) coupled to a full wave rectifier7025 implemented with diodes 91-94. The full wave rectifier 7025 iscoupled to the voltage regulator 7027. The output (OUT) of the voltageregulator 7027 is coupled to both the output terminals 7018, 7020 of themain power supply circuit 7010 (OP1) and the supplementary power supplycircuit 7014. An input capacitor C1 filters the input voltage in thevoltage regulator 7027 and one or more capacitors C2 filter the outputthe of the voltage regulator 7027.

In the embodiment illustrated in FIG. 117, the supplementary powersupply circuit 7014 comprises a pair of transistors T1, T2 configured tocontrol the power supply output OP2 between the electrical conductors7002, 7004. During normal operation when the electrical conductors 7002,7004 are not shorted, the output OP2 supplies power to the sensorcomponents 7005. Once the transistors T1 and T2 are turned ON(activated) and begin conducting current, the current from the output ofthe voltage regulator 7027 is shunted by the first transistor T1 suchthat no current flows through R1 and i_(R1)=0. The output voltage of theregulator +V is applied at the node such the V_(n)˜+V, which is then theoutput voltage OP2 of the supplementary power supply circuit 7014 andthe first transistor T1 drives the current to the sensor components 7005through the output terminal 7002, where output terminal 7004 is thecurrent return path. A portion of the output current i_(R5) is divertedthrough R5 to drive the output indicator LED2. The current though theLED2 is i_(R5). As long as the node voltage V_(n) is above the thresholdnecessary to turn ON (activate) the second transistor T2, thesupplementary power supply circuit 7014 operates as a power supplycircuit to feed the sensors and/or electronic components 7005.

When the electrical conductors 7002, 7004 of the secondary circuit areshorted, the node voltage V_(n) drops to ground or zero and the secondtransistor T2 turns OFF and stops conducting, which turns OFF the firsttransistor T1. When the first transistor T1 is cut-OFF, the outputvoltage +V of the voltage regulator 7027 causes current i_(R1) to flowthrough the short circuit indicator LED1 and through to ground via theshort circuit between the electrical conductors 7002, 7004. Thus, nocurrent flows through R5 and i_(R5)=0 A and +V_(OP2)=0V. Thesupplementary power supply circuit 7014 isolates itself from the mainpower supply circuit 7010 until the short circuit is removed. During theshort circuit only the short circuit indicator LED1 is energized whilethe output indicator LED2 is not. When the short circuit between theelectrical conductors 7002, 7004 is removed, the node voltage V_(n)rises until T2 turns ON and subsequently turning T1 ON. When T1 and T2are turned ON (are biased in a conducting state such as saturation),until the node voltage V_(n) reaches +V_(OP2) and the supplementarypower supply circuit 7014 resumes its power supply function for thesensor components 7005. Once the supplementary power supply circuit 7014restores its power supply function, the short circuit indicator LED1turns OFF and the output indicator LED2 turns ON. The cycle is repeatedin the event of another short circuit between the supplementary powersupply circuit 7014 electrical conductors 7002, 7004.

In one embodiment, a sample rate monitor is provided to enable powerreduction by limiting sample rates and/or duty cycle of the sensorcomponents when the surgical instrument is in a non-sensing state. FIG.118 is a block diagram of a surgical instrument electronic subsystem7022 comprising a sample rate monitor 7024 to provide power reduction bylimiting sample rates and/or duty cycle of the sensors and/or electroniccomponents 7005 of the secondary circuit when the surgical instrument isin a non-sensing state, according to one embodiment. As shown in FIG.118, the surgical instrument electronic subsystem 7022 comprises aprocessor 7008 coupled to a main power supply circuit 7010. The mainpower supply circuit 7010 is coupled to a sample rate monitor circuit7024. A supplementary power supply circuit 7014 is coupled to the samplerate 7024 as powers the sensors and/or electronic components 7005 viathe electrical conductors 7002, 7004. The primary circuit comprising theprocessor 7008 is coupled to a device state monitor 7026. In variousembodiments, the surgical instrument electronic subsystem 7022 providesreal time feedback about the compressibility and thickness of tissueusing the sensors and/or electronic components 7005 as previouslydescribed herein. The modular architecture of the surgical instrumentenables the configuration of custom modular shafts to employ functionjob specific technologies. To enable such additional functionality,electronic connection points and components are employed to transferboth power and signal between modular components of the surgicalinstrument. An increase in the number of sensors and/or electroniccomponents 7005 increases the power consumption of the surgicalinstrument system 7022 and creates the need for various techniques forreducing power consumption of the surgical instrument system 7022.

In one embodiment, to reduce power consumption, a surgical instrumentconfigured with sensors and/or electronic components 7005 (secondarycircuit) comprises a sample rate monitor 7024, which can be implementedas a hardware circuit or software technique to reduce the sample rateand/or duty cycle for the sensors and/or electronic components 7005. Thesample rate monitor 7024 operates in conjunction with the device statemonitor 7026. The device state monitor 7026 senses the state of variouselectrical/mechanical subsystems of the surgical instrument. In theembodiment illustrated in FIG. 118, the device state monitor 7026whether the state of the end effector is in an unclamped (State 1), aclamping (State 2), or a clamped (State 3) state of operation.

The sample rate monitor 7024 sets the sample rate and/or duty cycle forthe sensor components 7005 based on the state of the end effectordetermined by the device state monitor 7026. In one aspect, the samplerate monitor 7024 may set the duty cycle to about 10% when the endeffector is in State 1, to about 50% when the end effector is in State2, or about 20% when the end effector is in State 3. In various otherembodiments, the duty cycle and/or sample rate set by the sample ratemonitor 7024 may take on ranges of values. For example, in anotheraspect, the sample rate monitor 7024 may set the duty cycle to a valuebetween about 5% to about 15% when the end effector is in State 1, to avalue of about 45% to about 55% when the end effector is in State 2, orto a value of about 15% to about 25% when the end effector is in State3. In various other embodiments, the duty cycle and/or sample rate setby the sample rate monitor 7024 may take on additional ranges of values.For example, in another aspect, the sample rate monitor 7024 may set theduty cycle to a value between about 1% to about 20% when the endeffector is in State 1, to a value of about 20% to about 80% when theend effector is in State 2, or to a value of about 1% to about 50% whenthe end effector is in State 3. In various other embodiments, the dutycycle and/or sample rate set by the sample rate monitor 7024 may take onadditional ranges of values.

In one aspect, the sample rate monitor 7024 may be implemented bycreating a supplementary circuit/software coupled to a maincircuit/software. When the supplementary circuit/software determinesthat the surgical instrument system 7022 is in a non-sensing condition,the sample rate monitor 7024 enters the sensors and/or electroniccomponents 7005 into a reduced sampling or duty cycle mode reducing thepower load on the main circuit. The main power supply circuit 7010 willstill be active to supply power, so that the protected processor 7008 ofthe primary circuit can monitor the condition. When the surgicalinstrument system 7022 enters a condition requiring more rigoroussensing activity the sample rate monitor 7024 increases thesupplementary circuit sample rate or duty cycle. The circuit couldutilize a mixture of integrated circuits, solid state components,microprocessors, and firmware. The reduced sample rate or duty cyclemode circuit also may be monitored to indicate the condition to the enduser of the surgical instrument system 7022. The circuit/software mightalso be monitored to lockout the firing or function of the device in theevent the device is in the power saving mode.

In one embodiment, the sample rate monitor 7024 hardware circuit orsoftware technique reduce the sample rate and/or duty cycle for thesensors and/or electronic components 7005 to reduce power consumption ofthe surgical instrument. The reduced sample rate and/or duty cycle maybe monitored to indicate one or more conditions to the end user of thesurgical instrument. In the event of a reduced sample rate and/or dutycycle condition in the surgical instrument the protectioncircuit/software may be configured to lock-out the surgical instrumentfrom being fired or otherwise operated.

In one embodiment, the present disclosure provides an over currentand/or a voltage protection circuit for sensors and/or electroniccomponents of a surgical instrument. FIG. 119 is a block diagram of asurgical instrument electronic subsystem 7028 comprising an over currentand/or over voltage protection circuit 7030 for sensors and/orelectronic components 7005 of the secondary circuit of a surgicalinstrument, according to one embodiment. In various embodiments, thesurgical instrument electronic subsystem 7028 provides real timefeedback about the compressibility and thickness of tissue using thesensors and/or electronic components 7005 of the secondary circuit aspreviously described herein. The modular architecture of the surgicalinstrument enables the configuration of custom modular shafts to employfunction job specific technologies. To enable the sensors and/orelectronic components 7005, additional electronic connection points andcomponents to transfer both power and signal between modular componentsare added. There is potential for these additional conductors for thesensors and/or electronic components 7005 from the modular pieces to beshorted and or damaged causing large draws of current that could damagefragile processor 7008 circuits or and other electronic components ofthe primary circuit. In one embodiment, the over current/voltageprotection circuit 7030 protects the conductors for the sensors and/orelectronic components 7005 on a surgical instrument using asupplementary self-isolating/restoring circuit 7014 coupled to the mainpower supply circuit 7010. The operation of one embodiment of thesupplementary self-isolating/restoring circuit 7014 is described inconnection with FIG. 117 and will not be repeated here for concisenessand clarity of disclosure.

In one embodiment, to reduce electronic damage during large currentdraws in a sensing surgical instrument, the electronic subsystem 7028 ofthe surgical instrument comprises an over current/voltage protectioncircuit 7030 for the conductors for the sensors and/or electroniccomponents 7005. The over current/voltage protection circuit 7030 may beimplemented by creating a supplementary circuit coupled to a main powersupply circuit 7010 circuit. In the case that the supplementary circuitelectrical conductors 7002, 7004 experience higher levels of currentthan expected, the over current/voltage protection circuit 7030 isolatesthe current from the main power supply circuit 7010 circuit to preventdamage. The main power supply circuit 7010 circuit will still be activeto supply power, so that the protected main processor 7008 can monitorthe condition. When a large current draw in the supplementary powersupply circuit 7014 is remedied, the supplementary power supply circuit7014 rejoins the main power supply circuit 7010 and is available tosupply power to the sensors and/or electronic components 7005 (e.g., thesecondary circuit). The over current/voltage protection circuit 7030 mayutilize a mixture of integrated circuits, solid state components,micro-processors, firmware, circuit breaker, fuses, or PTC (positivetemperature coefficient) type technologies.

In various embodiments, the over current/voltage protection circuit 7030also may be monitored to indicate the over current/voltage condition tothe end user of the device. The over current/voltage protection circuit7030 also may be monitored to lockout the firing of the surgicalinstrument when the over current/voltage condition event is indicated.The over current/voltage protection circuit 7030 also may be monitoredto indicate one or more over current/voltage conditions to the end userof the device. In the event of over current/voltage condition in thedevice the over current/voltage protection circuit 7030 may lock-out thesurgical instrument from being fired or lock-out other operations of thesurgical instrument.

FIG. 120 is an over current/voltage protection circuit 7030 for sensorsand electronic components 7005 (FIG. 119) of the secondary circuit of asurgical instrument, according to one embodiment. The overcurrent/voltage protection circuit 7030 provides a current path during ahard short circuit (SHORT) at the output of the over current/voltageprotection circuit 7030, and also provides a path for follow-throughcurrent through a bypass capacitor C_(BYPASS) driven by stray inductanceL_(STRAY).

In one embodiment, the over current/voltage protection circuit 7030comprises a current limited switch 7032 with autoreset. The currentlimited switch 7032 comprises a current sense resistor R_(CS) coupled toan amplifier A. When the amplifier A senses a surge current above apredetermined threshold, the amplifier activates a circuit breaker CB toopen the current path to interrupt the surge current. In one embodiment,the current limited switch 7032 with autoreset may be implemented with aMAX1558 integrated circuit by Maxim. The current limited switch 7032with autoreset. Autoreset latches the switch 7032 off if it is shortedfor more than 20 ms, saving system power. The shorted output (SHORT) isthen tested to determine when the short is removed to automaticallyrestart the channel. Low quiescent supply current (45 μA) and standbycurrent (3 μA) conserve battery power in the surgical instrument. Thecurrent limited switch 7032 with autoreset safety features ensure thatthe surgical instrument is protected. Built-in thermal-overloadprotection limits power dissipation and junction temperature. Accurate,programmable current-limiting circuits, protects the input supplyagainst both overload and short-circuit conditions. Fault blanking of 20ms duration enables the circuit to ignore transient faults, such asthose caused when hot swapping a capacitive load, preventing falsealarms to the host system. In one embodiment, the current limited switch7032 with autoreset also features a reverse-current protection circuitryto block current flow from the output to the input when the switch 7032is off.

In one embodiment, the present disclosure provides a reverse polarityprotection for sensors and/or electronic components in a surgicalinstrument. FIG. 121 is a block diagram of a surgical instrumentelectronic subsystem 7040 with a reverse polarity protection circuit7042 for sensors and/or electronic components 7005 of the secondarycircuit according to one embodiment. Reverse polarity protection isprovided for exposed leads (electrical conductors 7002, 7004) of asurgical instrument using a supplementary self-isolating/restoringcircuit referred to herein as a supplementary power supply circuit 7014coupled to the main power supply circuit 7010. The reverse polarityprotection circuit 7042 may be monitored to indicate one or more reversepolarity conditions to the end user of the device. In the event ofreverse polarity applied to the device the protection circuit 7042 mightlock-out the device from being fired or other device criticaloperations.

In various embodiments, the surgical instruments described hereinprovide real time feedback about the compressibility and thickness oftissue using sensors and/or electronic components 7005. The modulararchitecture of the surgical instrument enables the configuration ofcustom modular shafts to employ job specific technologies. To enablesensors and/or electronic components 7005, both power and data signalsare transferred between the modular components. During the assembly ofmodular components there are typically exposed electrical conductorsthat when connected are used to transfer power and data signals betweenthe connected components. There is potential for these conductors tobecome powered with reverse polarity.

Accordingly, in one embodiment, the surgical instrument electronicsubsystem 7040 is configured to reduce electronic damage during theapplication of a reverse polarity connection 7044 in a sensing surgicalinstrument. The surgical instrument electronic subsystem 7040 employs apolarity protection circuit 7042 inline with the exposed electricalconductors 7002, 7004. In one embodiment, the polarity protectioncircuit 7042 may be implemented by creating a supplementary power supplycircuit 7014 coupled to a main power supply circuit 7010. In the casethat the supplementary power supply circuit 7014 electrical conductors7002, 7004 become powered with reverse polarity it isolates the powerfrom the main power supply circuit 7010 to prevent damage. The mainpower supply circuit 7010 will still be active to supply power, so thatthe protected processor 7008 of the main circuit can monitor thecondition. When the reverse polarity in the supplementary power supplycircuit 7014 is remedied, the supplementary power supply circuit 7014rejoins the main power supply circuit 7010 and is available to supplypower to the secondary circuit. The reverse polarity protection circuit7042 also may be monitored to indicate that the reverse polaritycondition to the end user of the device. The reverse polarity protectioncircuit 7042 also may be monitored to lockout the firing of the deviceif a reverse polarity event is indicated.

FIG. 122 is a reverse polarity protection circuit 7042 for sensorsand/or electronic components 7005 of the secondary circuit of a surgicalinstrument according to one embodiment. During normal operation, therelay switch S1 comprises output contacts in the normally closed (NC)position and the battery voltage B₁ of the main power supply circuit7010 (FIG. 121) is applied to V_(OUT) coupled to the secondary circuit.The diode D₁ blocks current from flowing through the coil 7046(inductor) of the relay switch S₁. When the polarity of the battery B₁is reversed, diode D₁ conducts and current flows through the coil 7046of the relay switch S_(i) energizing the relay switch S1 to place theoutput contacts in the normally open (NO) position and thusdisconnecting the reverse voltage from V_(OUT) coupled to the secondarycircuit. Once the switch S₁ is in the NO position, current from thepositive terminal of the battery B₁ flows through LED D₃ and resistor R₁to prevent the battery B₁ from shorting out. Diode D₂ is a clampingdiode to protect from spikes generated by the coil 7046 duringswitching.

In one embodiment, the surgical instruments described herein provide apower reduction technique utilizing a sleep mode for sensors on amodular device. FIG. 123 is a block diagram of a surgical instrumentelectronic subsystem 7050 with power reduction utilizing a sleep modemonitor 7052 for sensors and/or electronic components 7005 according toone embodiment. In one embodiment, the sleep mode monitor 7052 for thesensors and/or electronic components 7005 of the secondary circuit maybe implemented as a circuit and/or as a software routine to reduce thepower consumption of a surgical instrument. The sleep mode monitor 7052protection circuit may be monitored to indicate one or more sleep modeconditions to the end user of the device. In the event of a sleep modecondition in the device, the sleep mode monitor 7052 protectioncircuit/software may be configured to lock-out the device from beingfired or operated by the user.

In various embodiments, the surgical instruments described hereinprovide real time feedback about the compressibility and thickness oftissue using electronic sensors 7005. The modular architecture enablesthe surgical instrument to be configured with custom modular shafts toemploy job specific technologies. To enable sensors and/or electroniccomponents 7005, additional electronic connection points and componentsmay be employed to transfer both power and data signal between themodular components. As the number of sensors and/or electroniccomponents 7005 increases, the power consumption of the surgicalinstrument increases, thus creating a need for techniques to reduce thepower consumption of the surgical instrument.

In one embodiment, the electronic subsystem 7050 comprises a sleep modemonitor 7052 circuit and/or software for the sensors 7005 to reducepower consumption of the sensing surgical instrument. The sleep modemonitor 7052 may be implemented by creating a supplementary power supplycircuit 7014 coupled to a main power supply circuit 7010. A device statemonitor 7054 monitors whether the surgical instrument is in a1=Unclamped State, 2=Clamping State, or a 3=Clamped State. When thesleep mode monitor 7052 software determines that the surgical instrumentis in a non-sensing (1=Unclamped State) condition the sleep mode monitor7052 enters the sensors and/or electronic components 7005 of thesecondary circuit into a sleep mode to reduce the power load on the mainpower supply circuit 7010. The main power supply circuit 7010 will stillbe active to supply power, so that the protected processor 7008 of theprimary circuit can monitor the condition. When the surgical instrumententers a condition requiring sensor activity the supplementary powersupply circuit 7014 is awakened and rejoins the main power supplycircuit 7010. The sleep mode monitor 7051 circuit can utilize a mixtureof integrated circuits, solid state components, micro-processors, and/orfirmware. The sleep mode monitor 7051 circuit also may be monitored toindicate the condition to the end user of the device. The sleep modemonitor 7051 circuit may also be monitored to lockout the firing orfunction of the device in the event the device is in a sleep mode.

In one embodiment the present disclosure provides protection againstintermittent power loss for sensors and/or electronic components inmodular surgical instruments. FIG. 124 is a block diagram of a surgicalinstrument electronic subsystem 7060 comprising a temporary power losscircuit 7062 to provide protection against intermittent power loss forsensors and/or electronic components 7005 of the secondary circuit inmodular surgical instruments.

In various embodiments, the surgical instruments described hereinprovide real time feedback about the compressibility and thickness oftissue using sensors and/or electronic components 7005. The modulararchitecture enables the surgical instrument to be configured withcustom modular shafts to employ job specific technologies. To enablesensors and/or electronic components 7005 additional electronicconnection points and components may be employed to transfer both powerand signal between the modular components. As the number of electricalconnection points increase, the potential for sensors and/or electroniccomponents 7005 to experience short term intermittent power lossincreases.

In accordance with one embodiment, the temporary power loss circuit 7062is configured to reduce device operation error from short termintermittent power loss in a sensing surgical instrument. The temporarypower loss circuit 7062 has the capacity to deliver continuous power forshort periods of time in the event the power from the main power supplycircuit 7010 is interrupted. The temporary power loss circuit 7062 maycomprises capacitive elements, batteries, and/or other electronicelements capable of leveling, detecting, or storing power.

As shown in FIG. 124, the temporary power loss circuit 7062 may beimplemented by creating a supplementary circuit/software coupled to amain circuit/software. In the case that the supplementarycircuit/software experiences a sudden power loss from the main powersource, the sensors and/or electronic components 7005 powered by thesupplementary power supply circuit 7014 would be unaffected for shortperiod times. During the power loss the supplementary power supplycircuit 7014 may be powered by capacitive elements, batteries, and/orother electronic elements that are capable of leveling or storing power.The temporary power loss circuit 7062 implemented either in hardware orsoftware also may be monitored to lockout the firing or function of thesurgical instrument in the event the device is in the power saving mode.In the event of an intermittent power loss condition in the surgicalinstrument the temporary power loss circuit 7062 implemented either inhardware or software may lock-out the surgical instrument from beingfired or operated.

FIG. 125 illustrates one embodiment of a temporary power loss circuit7062 implemented as a hardware circuit. The temporary power loss circuit7062 hardware circuit is configured to reduce surgical instrumentoperation error from short term intermittent power loss. The temporarypower loss circuit 7062 has the capacity to deliver continuous power forshort periods of time in the event the power from the main power supplycircuit 7010 (FIG. 124) is interrupted. The temporary power loss circuit7062 employs capacitive elements, batteries, and/or other electronicelements that are capable of leveling, detecting, or storing power. Thetemporary power loss circuit 7062 may be monitored to indicate one ormore conditions to the end user of the surgical instrument. In the eventof an intermittent power loss condition in the surgical instrument, thetemporary power loss circuit 7062 protection circuit/software mightlock-out the device from being fired or operated.

In the illustrated embodiment, the temporary power loss circuit 7062comprises an analog switch integrated circuit U1. In one embodiment, theanalog switch integrated circuit U1 is a single-pole/single-throw(SPST), low-voltage, single-supply, CMOS analog switch such as theMAX4501 provided by Maxim. In one embodiment, the analog switchintegrated circuit U1 is normally open (NO). In other embodiments, theanalog switch integrated circuit U1 may be normally closed (NC). Theinput IN activates the NO analog switch 7064 to connect the output of astep-up DC-DC converter U3 to the input of a linear regulator U2 via astandby “RESERVE CAPACITOR.” The output of the linear regulator U2 iscoupled to the input of the DC-DC converter U3. The linear regulator U2maximizes battery life by combining ultra-low supply currents and lowdropout voltages. In one embodiment, the linear regulator U2 is a MAX882integrated circuit provided by Maxim.

The batteries are also coupled to the input of the step-up DC-DCconverter U3. The step-up DC-DC converter U3 may be a compact,high-efficiency, step-up DC-DC converter with a built-in synchronousrectifier to improve efficiency and reduce size and cost by eliminatingthe need for an external Schottky diode. In one embodiment, the step-upDC-DC converter U3 is a MAX1674 integrated circuit by Maxim.

Smart Cartridge Technology

FIGS. 126A and 126B illustrate one embodiment of an end effector 10000comprising a magnet 10008 and a Hall effect sensor 10010 incommunication with a processor 10012. The end effector 10000 is similarto the end effector 300 described above. The end effector comprises afirst jaw member, or anvil 10002, pivotally coupled to a second jawmember, or elongated channel 10004. The elongated channel 10004 isconfigured to operably support a staple cartridge 10006 therein. Thestaple cartridge 10006 is similar to the staple cartridge 304 describedabove. The anvil 10008 comprises a magnet 10008. The staple cartridgecomprises a Hall effect sensor 10010 and a processor 10012. The Halleffect sensor 10010 is operable to communicate with the processor 10012through a conductive coupling 10014. The Hall effect sensor 10010 ispositioned within the staple cartridge 10006 to operatively couple withthe magnet 10008 when the anvil 10002 is in a closed position. The Halleffect sensor 10010 can be configured to detect changes in the magneticfield surrounding the Hall effect sensor 10010 caused by the movement ofor location of magnet 10008.

FIG. 127 illustrates one embodiment of the operable dimensions thatrelate to the operation of the Hall effect sensor 10010. A firstdimension 10020 is between the bottom of the center of the magnet 10008and the top of the staple cartridge 10006. The first dimension 10020 canvary with the size and shape of the staple cartridge 10006, such as forinstance between 0.0466 inches, 0.0325 inches, 0.0154 inches, or 0.0154inches, or any reasonable value. A second dimension 10022 is between thebottom of the center of the magnet 10008 and the top of the Hall effectsensor 10010. The second dimension can also vary with the size and shapeof the staple cartridge 10006, such as for instance 0.0666 inches,0.0525 inches, 0.0354 inches, 0.0347 inches, or any reasonable value. Athird dimension 10024 is between the top of the processor 10012 and thelead-in surface 10028 of the staple cartridge 10006. The third dimensioncan also vary with the size and the shape of the staple cartridge, suchas for instance 0.0444 inches, 0.0440 inches, 0.0398 inches, 0.0356inches, or any reasonable value. An angle 10026 is the angle between theanvil 10002 and the top of the staple cartridge 10006. The angle 10026also can vary with the size and shape of the staple cartridge 10006,such as for instance 0.91 degrees, 0.68 degrees, 0.62 degrees, 0.15degrees, or any reasonable value.

FIGS. 128A through 128D further illustrate dimensions that can vary withthe size and shape of a staple cartridge 10006 and effect the operationof the Hall effect sensor 10010. FIG. 128A illustrates an external sideview of an embodiment of a staple cartridge 10006. The staple cartridge10006 comprises a push-off lug 10036. When the staple cartridge 10006 isoperatively coupled with the end effector 10000 as illustrated in FIG.126A, the push-off lug 10036 rests on the side of the elongated channel10004.

FIG. 128B illustrates various dimensions possible between the lowersurface 10038 of the push-off lug 10036 and the top of the Hall effectsensor 10010 (not pictured). A first dimension 10030 a is possible withblack, blue, green or gold staple cartridges 10006, where the color ofthe body of the staple cartridge 10006 may be used to identify variousaspects of the staple cartridge 10006. The first dimension 10030 a canbe, for instance, 0.005 inches below the lower surface 10038 of thepush-off lug 10036. A second dimension 10030 b is possible with graystaple cartridges 10006, and can be 0.060 inches above the lower surface10038 of the push-off lug 10036. A third dimension 10030 c is possiblewith white staple cartridges 10006, and can be 0.030 inches above thelower-surface 10038 of the push-off lug 10036.

FIG. 128C illustrates an external side view of an embodiment of a staplecartridge 10006. The staple cartridge 10006 comprises a push-off lug10036 with a lower surface 10038. The staple cartridge 10006 furthercomprises an upper surface 10046 immediately above the Hall effectsensor 10010 (not pictured). FIG. 128D illustrates various dimensionspossible between the lower surface 10038 of the push-off lug 10038 andthe upper surface 10046 of the staple cartridge 10006 above the Halleffect sensor 10010. A first dimension 10040 is possible for black,blue, green or gold staple cartridges 10006, and can be, for instance,0.015 inches above the lower surface 10038 of the push-off lug 10036. Asecond dimension 10042 is possible for gray staple cartridges 10006, andcan be, for instance, 0.080 inches. A third dimension 10044 is possiblefor white staple cartridges 10006, and can be, for instance, 0.050.

It is understood that the references to the color of the body of astaple cartridge 10006 is for convenience and by way of example only. Itis understood that other staple cartridge 10006 body colors arepossible. It is also understood that the dimensions given for FIGS. 128Athrough 128D are also example and non-limiting.

FIG. 129A illustrates various embodiments of magnets 10058 a-10058 d ofvarious sizes, according to how each magnet 10058 a-10058 d may fit inthe distal end of an anvil, such as anvil 10002 illustrated in FIGS.126A-126B. A magnet 10058 a-10058 d can be positioned in the distal tipof the anvil 10002 at a given distance 10050 from the anvil's pin orpivot point 10052. It is understood that this distance 10050 may varywith the construction of the end effector and staple cartridge and/orthe desired position of the magnet. FIG. 129B further illustrates afront-end cross-sectional view 10054 of the anvil 10002 and the centralaxis point of the anvil 10002. FIG. 129A also illustrates an example10056 of how various embodiments of magnets 10058 a-10058 d may fitwithin the same anvil 10002.

FIGS. 130A-130E illustrate one embodiment of an end effector 10100 thatcomprises, by way of example, a magnet 10058 a as illustrated in FIGS.129A-129B. FIG. 130A illustrates a front-end cross-sectional view of theend effector 10100. The end effector 10100 is similar to the endeffector 300 described above. The end effector 10100 comprises a firstjaw member or anvil 10102, a second jaw member or elongated channel10104, and a staple cartridge 10106 operatively coupled to the elongatedchannel 10104. The anvil 10102 further comprises the magnet 10058 a. Thestaple cartridge 10106 further comprises a Hall effect sensor 10110. Theanvil 10102 is here illustrated in a closed position. FIG. 130Billustrates a front-end cutaway view of the anvil 10102 and the magnet10058 a, in situ. FIG. 130C illustrates a perspective cutaway view ofthe anvil 10102 and the magnet 10058 a, in an optional location. FIG.130D illustrates a side cutaway view of the anvil 10102 and the magnet10058 a, in an optional location. FIG. 130E illustrates a top cutawayview of the anvil 10102 and the magnet 10058 a, in an optional location.

FIGS. 131A-131E illustrate one embodiment of an end effector 10150 thatcomprises, by way of example, a magnet 10058 d as illustrated in FIGS.129A-129B. FIG. 131A illustrates a front-end cross-sectional view of theend effector 10150. The end effector 10150 comprises an anvil 10152, anelongated channel 10154, and a staple cartridge 10156. The anvil 10152further comprises magnet 10058 d. The staple cartridge 10156 furthercomprises a Hall effect sensor 10160. FIG. 131B illustrates a front-endcutaway view of the anvil 10150 and the magnet 10058 d, in situ. FIG.131C illustrates a perspective cutaway view of the anvil 10152 and themagnet 10058 d in an optional location. FIG. 131D illustrates a sidecutaway view of the anvil 10152 and the magnet 10058 d in an optionallocation. FIG. 131E illustrates a top cutaway view of the anvil 10152and magnet 10058 d in an optional location.

FIG. 132 illustrates an end effector 300 as described above, andillustrates contact points between the anvil 306 and either the staplecartridge 304 and/or the elongated channel 302. Contact points betweenthe anvil 306 and the staple cartridge 304 and/or the elongated channel302 can be used to determine the position of the anvil 306 and/orprovide a point for an electrical contact between the anvil 306 and thestaple cartridge 304, and/or the anvil 306 and the elongated channel302. Distal contact point 10170 can provide a contact point between theanvil 306 and the staple cartridge 304. Proximal contact point 10172 canprovide a contact point between the anvil 306 and the elongated channel302.

FIGS. 133A and 133B illustrate one embodiment of an end effector 10200that is operable to use conductive surfaces at the distal contact pointto create an electrical connection. The end effector 10200 is similar tothe end effector 300 described above. The end effector comprises ananvil 10202, an elongated channel 10204, and a staple cartridge10206.The anvil 10202 further comprises a magnet 10208 and an inside surface10210, which further comprises a number of staple-forming indents 10212.In some embodiments, the inside surface 10210 of the anvil 10202 furthercomprises a first conductive surface 10214 surrounding thestaple-forming indents 10212. The first conductive surface 10214 cancome into contact with second conductive surfaces 10222 on the staplecartridge 10206, as illustrated in FIG. 107B. FIG. 107B illustrates aclose-up view of the cartridge body 10216 of the staple cartridge 10206.The cartridge body 10216 comprises a number of staple cavities 10218designed to hold staples (not pictured). In some embodiments the staplecavities 10218 further comprise staple cavity extensions 10220 thatprotrude above the surface of the cartridge body 10216. The staplecavity extensions 10220 can be coated with the second conductivesurfaces 10222. Because the staple cavity extensions 10222 protrudeabove the surface of the cartridge body 10216, the second conductivesurfaces 10222 will come into contact with the first conductive surfaces10214 when the anvil 10202 is in a closed position. In this manner theanvil 10202 can form an electrical contact with the staple cartridge10206.

FIGS. 134A-134C illustrate one embodiment of an end effector 10250 thatis operable to use conductive surfaces to form an electrical connection.FIG. 134A illustrates the end effector 10250 comprises an anvil 10252,an elongated channel 10254, and a staple cartridge 10256. The anvilfurther comprises a magnet 10258 and an inside surface 10260, whichfurther comprises staple-forming indents 10262. In some embodiments theinside surface 10260 of the anvil 10250 can further comprise firstconductive surfaces 10264, located, by way of example, distally from thestaple-forming indents 10262, as illustrated in FIG. 134B. The firstconductive surfaces 10264 are located such that they can come intocontact with a second conductive surface 10272 located on the staplecartridge 10256, as illustrated in FIG. 134C. FIG. 134C illustrates thestaple cartridge 10256, which comprises a cartridge body 10266. Thecartridge body 10266 further comprises an upper surface 10270, which insome embodiments can be coated with the second conductive surface 10272.The first conductive surfaces 10264 are located on the inside surface10260 of the anvil 10252 such that they come into contact with thesecond conductive surface 10272 when the anvil 10252 is in a closedposition. In this manner the anvil 10250 can form an electrical contactwith the staple cartridge 10256.

FIGS. 135A and 135B illustrate one embodiment of an end effector 10300that is operable to use conductive surfaces to form an electricalconnection. The end effector 10300 comprises an anvil 10302, anelongated channel 10304, and a staple cartridge 10306. The anvil 10302further comprises a magnet 10308 and an inside surface 10310, whichfurther comprises a number of staple-forming indents 10312. In someembodiments the inside surface 10310 further comprises a firstconductive surface 10314 surrounding some of the staple-forming indents10312. The first conductive surface is located such that it can comeinto contact with second conductive surfaces 10322 as illustrated inFIG. 135A. FIG. 135B illustrates a close-up view of the staple cartridge10306. The staple cartridge 10306 comprises a cartridge body 10316 whichfurther comprises an upper surface 10320. In some embodiments, theleading edge of the upper surface 10320 can be coated with secondconductive surfaces 10322. The first conductive surface 10312 ispositioned such that it will come into contact with the secondconductive surfaces 10322 when the anvil 10302 is in a closed position.In this manner the anvil 10302 can form an electrical connection withthe staple cartridge 10306.

FIGS. 136A and 136B illustrate one embodiment of an end effector 10350that is operable to use conductive surfaces to form an electricalconnection. FIG. 136A illustrates an end effector 10350 comprising ananvil 10352, an elongated channel 10354, and a staple cartridge 10356.The anvil 10352 further comprises a magnet 10358 and an inside surface10360, which further comprises a number of staple-forming indents 10362.In some embodiments the inside surface 10360 further comprises a firstconductive surface 10364 surrounding some of the staple-forming indents10362. The first conductive surface is located such that it can comeinto contact with second conductive surfaces 10372 as illustrated inFIG. 136B. FIG. 136B illustrates a close-up view of the staple cartridge10356. The staple cartridge 10356 comprises a cartridge body 10366 whichfurther comprises an upper surface 10370. In some embodiments, theleading edge of the upper surface 10327 can be coated with secondconductive surfaces 10372. The first conductive surface 10362 ispositioned such that it will come into contact with the secondconductive surfaces 10372 when the anvil 10352 is in a closed position.In this manner the anvil 10352 can form an electrical connection withthe staple cartridge 10356.

FIGS. 137A-137C illustrate one embodiment of an end effector 10400 thatis operable to use the proximal contact point 10408 to form anelectrical connection. FIG. 137A illustrate the end effector 10400,which comprises an anvil 10402, an elongated channel 10404, and a staplecartridge 10406.The anvil 10402 further comprises pins 10410 that extendfrom the anvil 10402 and allow the anvil to pivot between an open and aclosed position relative to the elongated channel 10404 and the staplecartridge 10406. FIG. 137B is a close-up view of a pin 10410 as it restswithin an aperture 10418 defined in the elongated channel 10404 for thatpurpose. In some embodiments, pin 10410 further comprises a firstconductive surface 10412 located on the exterior of the pin 10410. Insome embodiments the aperture 10418 further comprises a secondconductive surface 10141 on its outside surface. As the anvil 10402moves between a closed and an open position, the first conductivesurface 10412 on the pin 10410 rotates and comes into contact with thesecond conductive surface 10414 on the surface of the aperture 10418,thus forming an electrical contact. FIG. 137C illustrates an alternateembodiment, with an alternate location for a second conductive surface10416 on the surface of the aperture 10418.

FIG. 138 illustrates one embodiment of an end effector 10450 with adistal sensor plug 10466. End effector 10450 comprises a first jawmember or anvil 10452, a second jaw member or elongated channel 10454,and a staple cartridge 10466. The staple cartridge 10466 furthercomprises the distal sensor plug 10466, located at the distal end of thestaple cartridge 10466.

FIG. 139A illustrates the end effector 10450 with the anvil 10452 in anopen position. FIG. 139B illustrates a cross-sectional view of the endeffector 10450 with the anvil 10452 in an open position. As illustrated,the anvil 10452 may further comprise a magnet 10458, and the staplecartridge 10456 may further comprise the distal sensor plug 10466 and awedge sled, 10468, which is similar to the wedge sled 190 describedabove. FIG. 139C illustrates the end effector 10450 with the anvil 10452in a closed position. FIG. 139D illustrates a cross sectional view ofthe end effector 10450 with the anvil 10452 in a closed position. Asillustrated, the anvil 10452 may further comprise a magnet 10458, andthe staple cartridge 10456 may further comprise the distal sensor plug10466 and a wedge sled 10468. As illustrated, when the anvil 10452 is ina closed position relative to the staple cartridge 10456, the magnet10458 is in proximity to the distal sensor plug 10466.

FIG. 140 provides a close-up view of the cross section of the distal endof the end effector 10450. As illustrated, the distal sensor plug 10466may further comprise a Hall effect sensor 10460 in communication with aprocessor 10462. The Hall effect sensor 10460 can be operativelyconnected to a flex board 10464. The processor 10462 can also beoperatively connect to the flex board 10464, such that the flex board10464 provides a communication path between the Hall effect sensor 10460and the processor 10462. The anvil 10452 is illustrated in a closedposition, and as illustrated, when the anvil 10452 is in a closedposition the magnet 10458 is in proximity to the Hall effect sensor10460.

FIG. 141 illustrates a close-up top view of the staple cartridge 10456that comprises a distal sensor plug 10466. Staple cartridge 10456further comprises a cartridge body 10470. The cartridge body 10470further comprises electrical traces 10472. Electrical traces 10472provide power to the distal sensor plug 10466, and are connected to apower source at the proximal end of the staple cartridge 10456 asdescribed in further detail below. Electrical traces 10472 can be placedin the cartridge body 10470 by various methods, such as for instancelaser etching.

FIG. 142A and 142B illustrate one embodiment of a staple cartridge 10506with a distal sensor plug 10516. FIG. 142A is a perspective view of theunderside of the staple cartridge 10506. The staple cartridge 10506comprises a cartridge body 10520 and a cartridge tray 10522. The staplecartridge 10506 further comprises a distal sensor cover 10524 thatencloses the lower area of the distal end of the staple cartridge 10506.The cartridge tray 10522 further comprises an electrical contact 10526.FIG. 142B illustrates a cross sectional view of the distal end of thestaple cartridge 10506. As illustrated, the staple cartridge 10506 canfurther comprise a distal sensor plug 10516 located within the cartridgebody 10520. The distal sensor plug 10516 further comprises a Hall effectsensor 10510 and a processor 10512, both operatively connected to a flexboard 10514. The distal sensor plug 10516 can be connected to theelectrical contact 10526, and can thus use conductivity in the cartridgetray 10522 as a source of power. FIG. 142B further illustrates thedistal sensor cover 10524, which encloses the distal sensor plug 10516within the cartridge body 10520.

FIGS. 143A-143C illustrate one embodiment of a staple cartridge 10606that comprises a flex cable 10630 connected to a Hall effect sensor10610 and processor 10612. The staple cartridge 10606 is similar to thestaple cartridge 10606 is similar to the staple cartridge 306 describedabove. FIG. 143A is an exploded view of the staple cartridge 10606. Thestaple cartridge comprises 10606 a cartridge body 10620, a wedge sled10618, a cartridge tray 10622, and a flex cable 10630. The flex cable10630 further comprises electrical contacts 10632 at the proximal end ofthe staple cartridge 10606, placed to make an electrical connection whenthe staple cartridge 10606 is operatively coupled with an end effector,such as end effector 10800 described below. The electrical contacts10632 are integrated with cable traces 10634, which extend along some ofthe length of the staple cartridge 10606. The cable traces 10634 connect10636 near the distal end of the staple cartridge 10606 and thisconnection 10636 joins with a conductive coupling 10614. A Hall effectsensor 10610 and a processor 10612 are operatively coupled to theconductive coupling 10614 such that the Hall effect sensor 10610 and theprocessor 10612 are able to communicate.

FIG. 143B illustrates the assembly of the staple cartridge 10606 and theflex cable 10630 in greater detail. As illustrated, the cartridge tray10622 encloses the underside of the cartridge body 10620, therebyenclosing the wedge sledge 10618. The flex cable 10630 can be located onthe exterior of the cartridge tray 10622, with the conductive coupling10614 positioned within the distal end of the cartridge body 10620 andthe electrical contacts 10632 located on the outside near the proximalend. The flex cable 10630 can be placed on the exterior of the cartridgetray 10622 by any appropriate means, such as for instance bonding orlaser etching.

FIG. 143C illustrates a cross sectional view of the staple cartridge10606 to illustrate the placement of the Hall effect sensor 10610,processor 10612, and conductive coupling 10614 within the distal end ofthe staple cartridge, in accordance with the present embodiment.

FIG. 144A-144F illustrate one embodiment of a staple cartridge 10656that comprises a flex cable 10680 connected to a Hall effect sensor10660 and a processor 10662. FIG. 144A is an exploded view of the staplecartridge 10656. The staple cartridge comprises a cartridge body 10670,a wedge sled 10668, a cartridge tray 10672, and a flex cable 10680. Theflex cable 10680 further comprises cable traces 10684 that extend alongsome of the length of the staple cartridge 10656. Each of the cabletraces 10684 have an angle 10686 near their distal end, and connecttherefrom to a conductive coupling 10664. A Hall effect sensor 10660 anda processor 10662 are operatively coupled to the conductive coupling10664 such that the Hall effect sensor 10660 and the processor 10662 areable to communicate.

FIG. 144B illustrates the assembly of the staple cartridge 10656. Thecartridge tray 10672 encloses the underside of the cartridge body 10670,thereby enclosing the wedge sled 10668. The flex cable 10680 is locatedbetween the cartridge body 10670 and the cartridge tray 10672. As such,in the illustration only the angle 10686 and the conductive coupling10664 are visible.

FIG. 144C illustrates the underside of an assembled staple cartridge10656, and also illustrates the flex cable 10680 in greater detail. Inan assembled staple cartridge 10656, the conductive coupling 10664 islocated in the distal end of the staple cartridge 10656. Because theflex cable 10680 can be located between the cartridge body 10670 and thecartridge tray 10672, only the angle 10686 ends of the cable traces10684 would be visible from the underside of the staple cartridge 10656,as well as the conductive coupling 10664.

FIG. 144D illustrates a cross sectional view of the staple cartridge10656 to illustrate the placement of the Hall effect sensor 10660,processor 10662, and conductive coupling 10664. Also illustrated is anangle 10686 of a cable trace 10684, to illustrate where the angle 10686could be placed. The cable traces 10684 are not pictured.

FIG. 144E illustrates the underside of the staple cartridge 10656without the cartridge tray 10672 and including the wedge sled 10668, inits most distal position. The staple cartridge 10656 is illustratedwithout the cartridge tray 10672 in order to illustrate a possibleplacement for the cable traces 10684, which are otherwise obscured bythe cartridge tray 10672. As illustrated, the cable traces 10684 can beplaced inside the cartridge body 10670. The angle 10686 optionallyallows the cable traces 10684 to occupy a narrower space in the distalend of the cartridge body 10670.

FIG. 144F also illustrates the staple cartridge 10656 without thecartridge tray 10672 in order to illustrate a possible placement for thecable traces 10684. As illustrated the cable traces 10684 can be placedalong the length of the exterior of cartridge body 10670. Furthermore,the cable traces 10684 can form an angle 10686 to enter the interior ofthe distal end of the cartridge body 10670.

FIG. 145A and 145B illustrates one embodiment of a staple cartridge10706 that comprises a flex cable 10730, a Hall effect sensor 10710, anda processor 10712. FIG. 145A is an exploded view of the staple cartridge10706. The staple cartridge 10706 comprises a cartridge body 10720, awedge sled 10718, a cartridge tray 10722, and a flex cable 10730. Theflex cable 10730 further comprises electrical contacts 10732 placed tomake an electrical connection when the staple cartridge 10706 isoperatively coupled with an end effector. The electrical contacts 10732are integrated with cable traces 10734. The cable traces connect 10736near the distal end of the staple cartridge 10706, and this connection10736 joins with a conductive coupling 10714. A Hall effect sensor 10710and a processor 10712 are operatively connected to the conductivecoupling 10714 such that the are able to communicate.

FIG. 145B illustrates the assembly of the staple cartridge 10706 and theflex cable 10730 in greater detail. As illustrated, the cartridge tray10722 encloses the underside of the cartridge body 10720, therebyenclosing the wedge sled 10718. The flex cable 10730 can be located onthe exterior of the cartridge tray 10722 with the conductive coupling10714 positioned within the distal end of the cartridge body 10720. Theflex cable 10730 can be placed on the exterior of the cartridge tray10722 by any appropriate means, such as for instance bonding or laseretching.

FIGS. 146A-146F illustrate one embodiment of an end effector 10800 witha flex cable 10840 operable to provide power to a staple cartridge 10806that comprises a distal sensor plug 10816. The end effector 10800 issimilar to the end effector 300 described above. The end effector 10800comprises a first jaw member or anvil 10802, a second jaw member orelongated channel 10804, and a staple cartridge 10806 operativelycoupled to the elongated channel 10804. The end effector 10800 isoperatively coupled to a shaft assembly 10900. The shaft assembly 10900is similar to shaft assembly 200 described above. The shaft assembly10900 further comprises a closure tube 10902 that encloses the exteriorof the shaft assembly 10900. In some embodiments the shaft assembly10900 further comprises an articulation joint 10904, which includes adouble pivot closure sleeve assembly 10906. The double pivot closuresleeve assembly 10906 includes an end effector closure sleeve assembly10908 that is operable to couple with the end effector 10800.

FIG. 146A illustrates a perspective view of the end effector 10800coupled to the shaft assembly 10900. In various embodiments, the shaftassembly 10900 further comprises a flex cable 10830 that is configuredto not interfere with the function of the articulation joint 10904, asdescribed in further detail below. FIG. 146B illustrates a perspectiveview of the underside of the end effector 10800 and shaft assembly10900. In some embodiments, the closure tube 10902 of the shaft assembly10900 further comprises a first aperture 10908, through which the flexcable 10908 can extend. The close sleeve assembly 10908 furthercomprises a second aperture 10910, through which the flex cable 10908can also pass.

FIG. 146C illustrates the end effector 10800 with the flex cable 10830and without the shaft assembly 10900. As illustrated, in someembodiments the flex cable 10830 can include a single coil 10832operable to wrap around the articulation joint 10904, and thereby beoperable to flex with the motion of the articulation joint 10904.

FIG. 146D and 146E illustrate the elongated channel 10804 portion of theend effector 10800 without the anvil 10802 or the staple cartridge10806, to illustrate how the flex cable 10830 can be seated within theelongated channel 10804. In some embodiments, the elongated channel10804 further comprises a third aperture 10824 for receiving the flexcable 10830. Within the body of the elongated channel 10804 the flexcable splits 10834 to form extensions 10836 on either side of theelongated channel 10804. FIG. 146E further illustrates that connectors10838 can be operatively coupled to the flex cable extensions 10836.

FIG. 146F illustrates the flex cable 10830 alone. As illustrated, theflex cable 10830 comprises a single coil 10832 operative to wrap aroundthe articulation joint 10904, and a split 10834 that attaches toextensions 10836. The extensions can be coupled to connectors 10838 thathave on their distal facing surfaces prongs 10840 for coupling to thestaple cartridge 10806, as described below.

FIG. 147 illustrates a close up view of the elongated channel 10804 witha staple cartridge 10806 coupled thereto. The staple cartridge 10804comprises a cartridge body 10822 and a cartridge tray 10820. In someembodiments the staple cartridge 10806 further comprises electricaltraces 10828 that are coupled to proximal contacts 10856 at the proximalend of the staple cartridge 10806. The proximal contacts 10856 can bepositioned to form a conductive connection with the prongs 10840 of theconnectors 10838 that are coupled to the flex cable extensions 10836.Thus, when the staple cartridge 10806 is operatively coupled with theelongated channel 10804, the flex cable 10830, through the connectors10838 and the connector prongs 10840, can provide power to the staplecartridge 10806.

FIGS. 148A-148D further illustrate one embodiment of a staple cartridge10806 operative with the present embodiment of an end effector 10800.FIG. 148A illustrates a close up view of the proximal end of the staplecartridge 10806. As discussed above, the staple cartridge 10806comprises electrical traces 10828 that, at the proximal end of thestaple cartridge 10806, form proximal contacts 10856 that are operableto couple with the flex cable 10830 as described above. FIG. 148Billustrates a close-up view of the distal end of the staple cartridge10806, with a space for a distal sensor plug 10816, described below. Asillustrated, the electrical traces 10828 can extend along the length ofthe staple cartridge body 10822 and, at the distal end, form distalcontacts 10856. FIG. 148C further illustrates the distal sensor plug10816, which in some embodiments is shaped to be received by the spaceformed for it in the distal end of the staple cartridge 10806. FIG. 148Dillustrates the proximal-facing side of the distal sensor plug 10816. Asillustrated, the distal sensor plug 10816 has sensor plug contacts10854, positioned to couple with the distal contacts 10858 of the staplecartridge 10806. Thus, in some embodiments the electrical traces 10828can be operative to provide power to the distal sensor plug 10816.

FIGS. 149A and 149B illustrate one embodiment of a distal sensor plug10816. FIG. 149A illustrates a cutaway view of the distal sensor plug10816. As illustrated, the distal sensor plug 10816 comprises a Halleffect sensor 10810 and a processor 10812. The distal sensor plug 10816further comprises a flex board 10814. As further illustrated in FIG.149B, the Hall effect sensor 10810 and the processor 10812 areoperatively coupled to the flex board 10814 such that they are capableof communicating.

FIG. 150 illustrates an embodiment of an end effector 10960 with a flexcable 10980 operable to provide power to sensors and electronics 10972in the distal tip of the anvil 19052 portion. The end effector 10950comprises a first jaw member or anvil 10962, a second jaw member orelongated channel 10964, and a staple cartridge 10956 operativelycoupled to the elongated channel 10952. The end effector 10960 isoperatively coupled to a shaft assembly 10960. The shaft assembly 10960further comprises a closure tube 10962 that encloses the shaft assembly10960. In some embodiments the shaft assembly 10960 further comprises anarticulation joint 10964, which includes a double pivot closure sleeveassembly 10966.

In various embodiments, the end effector 10950 further comprises a flexcable 19080 that is configured to not interfere with the function of thearticulation joint 10964. In some embodiments, the closure tube 10962comprises a first aperture 10968 through which the flex cable 10980 canextend. In some embodiments, flex cable 10980 further comprises a loopor coil 10982 that wraps around the articulation joint 10964 such thatthe flex cable 10980 does not interfere with the operation of thearticulation joint 10964, as further described below. In someembodiments, the flex cable 10980 extends along the length of the anvil10951 to a second aperture 10970 in the distal tip of the anvil 10951.

FIGS. 151A-151C illustrate the operation of the articulation joint 10964and flex cable 19080 of the end effector 10950. FIG. 151A illustrates atop view of the end effector 10952 with the end effector 109650 pivoted−45 degrees with respect to the shaft assembly 10960. As illustrated,the coil 10982 of the flex cable 10980 flexes with the articulationjoint 10964 such that the flex cable 10980 does not interfere with theoperation of the articulation joint. 10964. FIG. 151B illustrates a topview of the end effector 10950. As illustrated, the coil 10982 wrapsaround the articulation joint 10964 once. FIG. 151C illustrates a topview of the end effector 10950 with the end effector 10950 pivoted +45degrees with respect to the shaft assembly 10960. As illustrated, thecoil 10982 of the flex cable 10980 flexes with the articulation joint10964 such that the flex cable 10980 does not interfere with theoperation of the articulation joint 10964.

FIG. 152 illustrates cross-sectional view of the distal tip of anembodiment of an anvil 10952 with sensors and electronics 10972. Theanvil 10952 comprises a flex cable 10980, as described with respect toFIGS. 150 and 151A-151C. As illustrated in FIG. 152, the anvil 10952further comprises a second aperture 10970 through which the flex cable10980 can pass such that the flex cable 10980 can enter a housing 10974in the within the anvil 10952. Within the housing 10974 the flex cable10980 can operably couple to sensors and electronics 10972 locatedwithin the housing 10974 and thereby provide power to the sensors andelectronics 10972.

FIG. 153 illustrates a cutaway view of the distal tip of the anvil10952. FIG. 153 illustrates an embodiment of the housing 10974 that cancontain sensors and electronics 10972 as illustrated by FIG. 152.

In accordance with various embodiments, the surgical instrumentsdescribed herein may comprise one or more processors (e.g.,microprocessor, microcontroller) coupled to various sensors. Inaddition, to the processor(s), a storage (having operating logic) andcommunication interface, are coupled to each other.

As described earlier, the sensors may be configured to detect andcollect data associated with the surgical device. The processorprocesses the sensor data received from the sensor(s).

The processor may be configured to execute the operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various embodiments, the operating logic may be configured to performthe initial processing, and transmit the data to the computer hostingthe application to determine and generate instructions. For theseembodiments, the operating logic may be further configured to receiveinformation from and provide feedback to a hosting computer. Inalternate embodiments, the operating logic may be configured to assume alarger role in receiving information and determining the feedback. Ineither case, whether determined on its own or responsive to instructionsfrom a hosting computer, the operating logic may be further configuredto control and provide feedback to the user.

In various embodiments, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other embodiments, theoperating logic may be implemented in hardware such as a gate array.

In various embodiments, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various embodiments, the communication interfacemay be a wired or a wireless communication interface. An example of awired communication interface may include, but is not limited to, aUniversal Serial Bus (USB) interface. An example of a wirelesscommunication interface may include, but is not limited to, a Bluetoothinterface.

For various embodiments, the processor may be packaged together with theoperating logic. In various embodiments, the processor may be packagedtogether with the operating logic to form a SiP. In various embodiments,the processor may be integrated on the same die with the operatinglogic. In various embodiments, the processor may be packaged togetherwith the operating logic to form a System on Chip (SoC).

Various embodiments may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some embodiments also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some embodiments may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other embodiments, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, ASICs, PLDs, DSPs, FPGAs, logic gates,registers, semiconductor device, chips, microchips, chip sets, and soforth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether an embodiment is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application APIs, and so forth. The firmware may be stored in amemory of the controller and/or the controller which may comprise anonvolatile memory (NVM), such as in bit-masked ROM or flash memory. Invarious implementations, storing the firmware in ROM may preserve flashmemory. The NVM may comprise other types of memory including, forexample, programmable ROM (PROM), erasable programmable ROM (EPROM),EEPROM, or battery backed RAM such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various embodiments may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more embodiments. In variousembodiments, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The embodiments,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with theembodiments disclosed herein may be implemented in the general contextof computer executable instructions, such as software, control modules,logic, and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some embodiments also may be practicedin distributed computing environments where operations are performed byone or more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the embodiments describedherein illustrate example implementations, and that the functionalelements, logical blocks, modules, and circuits elements may beimplemented in various other ways which are consistent with thedescribed embodiments. Furthermore, the operations performed by suchfunctional elements, logical blocks, modules, and circuits elements maybe combined and/or separated for a given implementation and may beperformed by a greater number or fewer number of components or modules.As will be apparent to those of skill in the art upon reading thepresent disclosure, each of the individual embodiments described andillustrated herein has discrete components and features which may bereadily separated from or combined with the features of any of the otherseveral aspects without departing from the scope of the presentdisclosure. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

It is worthy to note that any reference to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is comprisedin at least one embodiment. The appearances of the phrase “in oneembodiment” or “in one aspect” in the specification are not necessarilyall referring to the same embodiment.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some embodiments may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someembodiments may be described using the terms “connected” and/or“coupled” to indicate that two or more elements are in direct physicalor electrical contact with each other. The term “coupled,” however, alsomay mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other. Withrespect to software elements, for example, the term “coupled” may referto interfaces, message interfaces, API, exchanging messages, and soforth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The disclosed embodiments have application in conventional endoscopicand open surgical instrumentation as well as application inrobotic-assisted surgery.

Embodiments of the devices disclosed herein can be designed to bedisposed of after a single use, or they can be designed to be usedmultiple times. Embodiments may, in either or both cases, bereconditioned for reuse after at least one use. Reconditioning mayinclude any combination of the steps of disassembly of the device,followed by cleaning or replacement of particular pieces, and subsequentreassembly. In particular, embodiments of the device may bedisassembled, and any number of the particular pieces or parts of thedevice may be selectively replaced or removed in any combination. Uponcleaning and/or replacement of particular parts, embodiments of thedevice may be reassembled for subsequent use either at a reconditioningfacility, or by a surgical team immediately prior to a surgicalprocedure. Those skilled in the art will appreciate that reconditioningof a device may utilize a variety of techniques for disassembly,cleaning/replacement, and reassembly. Use of such techniques, and theresulting reconditioned device, are all within the scope of the presentapplication.

By way of example only, embodiments described herein may be processedbefore surgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device may also be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated can also be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically mateable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more embodiments has been presented for purposes ofillustration and description. It is not intended to be exhaustive orlimiting to the precise form disclosed. Modifications or variations arepossible in light of the above teachings. The one or more embodimentswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the various embodiments and with various modifications as aresuited to the particular use contemplated. It is intended that theclaims submitted herewith define the overall scope.

1. An electronic system for a surgical instrument, the electronic systemcomprising: a main power supply circuit configured to supply electricalpower to a primary circuit; a supplementary power supply circuitconfigured to supply electrical power to a secondary circuit; and ashort circuit protection circuit coupled between the main power supplycircuit and the supplementary power supply circuit; wherein thesupplementary power supply circuit is configured to isolate itself fromthe main power supply circuit when the supplementary power supplycircuit detects a short circuit condition at the secondary circuit; andwherein the supplementary power supply circuit is configured to rejointhe main power supply circuit and supply power to the secondary circuit,when the short circuit condition is remedied.
 2. The electronic systemof claim 1, wherein the short circuit protection circuit is configuredto monitor one or more short circuit conditions.
 3. The electronicsystem of claim 1, wherein short circuit protection circuit isconfigured to lockout the firing of the surgical instrument when a shortcircuit event is indicated.
 4. The electronic system of claim 1,comprising a plurality of supplementary protection circuits networkedtogether to isolate, detect, or protect other circuit functions.
 5. Anelectronic system for a surgical instrument, the electronic system,comprising: a main power supply circuit configured to supply electricalpower to a primary circuit; a supplementary power supply circuitconfigured to supply electrical power to a secondary circuit; and asample rate monitor coupled between the main power supply circuit andthe supplementary power supply circuit, wherein the sample rate monitoris configured to limit sample rates and/or duty cycle of the secondarycircuit when the surgical instrument is in a non-sensing state.
 6. Theelectronic system of claim 5, further comprising a device state monitorcoupled to the primary circuit, the device state monitor configured tosense a state of various electrical and mechanical subsystems of thesurgical instrument.
 7. The electronic system of claim 6, wherein thesample rate monitor operates in conjunction with the device statemonitor.
 8. The electronic system of claim 7, wherein the device statemonitor is configured to sense the state of an end effector of thesurgical instrument in an unclamped (State 1), a clamping (State 2), ora clamped (State 3) state of operation and wherein the sample ratemonitor is configured to set the sample rate and/or duty cycle for thesecondary circuit based on the state of the end effector determined bythe device state monitor.
 9. The electronic system of claim 8, whereinthe sample rate monitor is configured to set the duty cycle to about 10%when the end effector is in State 1, to about 50% when the end effectoris in State 2, or about 20% when the end effector is in State
 3. 10. Anelectronic system for a surgical instrument, the electronic system,comprising: a main power supply circuit configured to supply electricalpower to a primary circuit; a supplementary power supply circuitconfigured to supply electrical power to a secondary circuit; and anover current/voltage protection circuit coupled between the main powersupply circuit and the supplementary power supply circuit, wherein theover current/voltage protection circuit is configured to isolate currentfrom the main power supply circuit when the secondary circuitexperiences higher levels of current or voltage than expected.
 11. Theelectronic system of claim 10, wherein when the over current or the overvoltage condition is remedied, the supplementary power circuit rejoinsthe main power supply circuit and is configured to supply power to thesecondary circuit.
 12. The electronic system of claim 10, wherein theover current/voltage protection circuit is configured to lockout thefiring of the surgical instrument when the over current/voltagecondition event is indicated, when an over current/voltage condition isdetected.
 13. The electronic system of claim 10, wherein the overcurrent/voltage protection circuit is configured to indicate an overcurrent/voltage condition to an end user of the surgical instrument,when an over current/voltage condition is detected.
 14. The electronicsystem of claim 10, wherein the over current/voltage protection circuitis configured to lock-out the surgical instrument from being fired orlock-out other operations of the surgical instrument, when an overcurrent/voltage condition is detected. 15-25. (canceled)